Bal - 17212-02-02 LTM 1220-5.2 G-12

LIEBHERR
Mobile crane with telescopic boom
LTM 1220-5.2
LTM 1220-5-2-006
Operating instructions
BAL-No.: 17212-02-02
Pages: 1183
Works-Number
Date
ORIGINAL OPERATING MANUAL
The operating manual is part of the crane!
It must always be available within reach!
The traffic regulations and those for crane operation

must be observed!
Liebherr-Werk Ehingen GmbH

Postfach 1361
D-89582 Ehingen / Donau
: +49 (0) 7391 502–0
Fax: +49 (0) 7391 502–3399
: info.lwe@liebherr.com
www.liebherr.com
1
Foreword
General
This crane was built according to the state of technology and recognized safety technical regulations.
Despite that, dangers to body and life for the user and / or third persons or damage to the crane and /
or other material assets can occur.
This crane may only be used in flawless technical condition and according to its mission as well as
with constant awareness of safety and dangers. Any problems, which could affect safety must be
fixed immediately.
Modifications on the crane may only be made with written approval by Liebherr-Werk Ehingen GmbH.
This crane is equipped with a data recording device. The following data is recorded:
– Date, time
– Selected configuration (boom configuration, ballast, outrigger extension, reeving, hook block)
– Actual load
– Percentage of loading the crane
– Working radius
– Main boom angle, luffing jib angle
– Total length of tele boom, length of each tele section
– All bridging devices
The recorded data can be real with the respective software.
Warning notes
The terms DANGER, WARNING, CAUTION and ATTENTION used in these operating instructions
are intended to point out certain rules of conduct to all persons working with the crane.
Warn- Signal word Explanation

ing
signs
DANGER Designates a dangerous situation which will lead to death or serious injury
if it is not prevented.
WARNING Designates a dangerous situation, which can lead to death or serious injury
if it is not prevented.
CAUTION Designates a dangerous situation, which can lead to slight or

medium-grade injuries if it is not prevented.
ATTENTION Designates a dangerous situation, which can lead to property damage if it

is not prevented.
Additional notes
The term Note is used in these operating instructions to indicate useful information and tips to all
persons working with the crane.
2 LIEBHERR
0.01 Foreword 028189-00
Sign Signal word Explanation

Note Designates useful information and tips.
Operating instructions
These operating instructions are intended to put you in a position to operate the crane safely and
utilize the reliable usage options that it provides. The instructions also provide information about the
function of important components and systems.
Certain expressions are used in these operating instructions. In order to avoid misunderstandings, the
same expressions should always be used.
These operating instructions have been translated to be best of one’s knowledge. Liebherr-Werk
Ehingen GmbH assumes no liability for translation errors. The German version of these operating
instructions is solely applicable for factual accuracy. If you find any errors or if any misunderstandings
arise when reading these operating instructions, please contact Liebherr-Werk Ehingen GmbH
immediately.
DANGER
Risk of fatal injury if operated incorrectly!
Incorrect operation of the crane can result in death or serious injuries!
Only authorised and trained expert personnel are permitted to work on the crane!
The operating instructions and on-site regulations and specifications (such as accident prevention
regulations) must be followed.
The use of these operating instructions:
– makes it easier to become familiar with the crane
– avoids problems due to improper operation
Observing these operating instructions:
– increases reliability in use
– extends the service life of your crane
– reduces repair costs and downtime
Always keep these operating instructions handy in the driver's or crane cab.
The operating manual is part of the crane!
Only operate the crane if you are well familiarized with the equipment, and always follow these
operating instructions.
Note
If you have received additional information about the crane from us, such as technical information
bulletins, instructions and/or supplements to these operating instructions, then this information
must also be followed and kept with the operating instructions.
If there is anything in the operating instructions or the individual chapters that you do not understand,
please contact us before starting the relevant work.
The information and illustrations contained in these operating instructions may not be copied or
distributed, nor used for the purposes of competition. All rights are expressly reserved in accordance
with copyright laws.
All accident prevention guidelines, operating instructions, etc. are based on destined use of the crane.
0.01 LIEBHERR 3
028189-00 0.01 Foreword
B110001
4 LIEBHERR 0.01
0.01 Foreword 028189-00
Destined use
The destined use of the crane consists solely in vertical lifting and lowering of free and non-adhered
loads, whose weight and center of gravity are known.
To do so, a hook or hook block approved by Liebherr must be reeved on the hoist rope and it may
only be operated within the permissible crane configurations.
Driving with the crane, with or without an attached load is only permissible if a corresponding driving
or load chart is available. The crane configurations intended for it and the safety conditions must be
observed according to the corresponding operating instructions.
Any other use or any other exceeding utilization is not destined use.
Part of destined use is also adherence of required safety regulations, conditions, preconditions, crane
configurations and working steps as noted in the crane documentation (operating instructions, load
chart, job planner).
The manufacturer is not liable for damages, which are caused by non-destined use or improper use
of the crane. Any associated risk it is carried solely by the owner, the operator and the user of the
crane.
Note
Crane with “CE-mark” according to the European machinery directive 2006/42/EC and the EN
13000! Illustration 1
It is prohibited to bring the crane into service and to operate it within the European Union without a
“CE-mark”! Illustration 2
It is prohibited to operate cranes with a tipping load utilization of 85% which are programmed
according to ASME B30.5 within the European Union or in countries which permit a lower
stationary stability utilization (for example according to ISO 4305)! These cranes may not have a
“CE-mark”! Illustration 2
0.01 LIEBHERR 5
028189-00 0.01 Foreword
Non-destined use
Non -destined use is:
– Working outside the permissible crane configurations according to the load chart
– Working outside the permissible projection radii and slewing ranges according to the load chart
– Selecting load values, which do not correspond to the actual crane configuration
– Selecting LMB-Codes, which do not match the actual crane configuration
– Working with bypassed load moment limiter or bypassed hoist limit switch
– Increasing the projection radius of the lifted load after a LMB shut off, for example by diagonally
pulling the load
– Using the support pressure display as a safety function against tipping over
– Using equipment or attachment parts which are not approved for the crane
– Using the crane at sports and recreational events, especially for 'Bungee' jumps
– Driving on a public road in non-permissible driving condition (axle load, dimension)
– Driving with the equipment in place in a non-permissible driving condition
– Pushing, pulling or lifting loads with the leveling regulation, the sliding beams or the support
cylinders
– Pushing, pulling or lifting loads by actuating the slewing gear, the luffing gear or the telescoping
gear
– Ripping stuck objects loose with the crane
– Utilizing the crane for a longer period of time for material handling tasks
– Releasing the crane suddenly (grapple or dumping operation)
– Utilizing the crane when the weight of the load, which is suspended load on the crane, is changed,
for example by filling a container suspended on the load hook, except:
• The load moment limiter was checked before for function with a known load.
• The crane operator's cab is occupied and the crane is operational.
• The container size is selected in such a way that an overload of the crane with full load is
eliminated within the valid used load chart.
The crane may not be used for:
– Aattaching a stuck load for which the weight and center of gravity are not known and which is
released first, for example with a cutting torch
– Letting persons drive along outside the driver's cab
– Transporting personnel in the crane cab while driving
– Transporting personnel with the lifting equipment and on the load
– Transporting of persons with work baskets (cherry pickers), if the national regulations of the
responsible work safety organization are not observed
– Transporting loads on the chassis
– Two hook operation without auxiliary equipment
– Extended material handling operation
– Crane operation on a barge if the conditions are not determined and the written release by
Liebherr Werk Ehingen GmbH is not present
The operating instructions must be read and used by all persons who are involved in the usage,
operation, assembly and maintenance of the crane.
Safety systems
Special attention must be paid to the safety equipment built into the crane. The functionality of the
safety equipment must be monitored at all times. The crane may not be operated if the safety
equipment is not working or not working correctly.
Note
Your motto must always be:
Safety first!
The crane had been built in accordance with the applicable crane operating and driving regulations
and have been approved by the relevant authorities.
Attachment and spare parts
6 LIEBHERR 0.01
0.01 Foreword 028189-00
DANGER
Danger to life if original attachment parts are not used!
If the crane is operated with attachment parts, which are not original, then the crane can fail and
cause fatal accidents!
Crane components can be damaged!
Operate the crane only with original attachment parts!
Crane operation with attachment parts, which do not belong to the crane is prohibited!
DANGER
The crane permit and the manufacturer's warranty will become void!
If any original installed parts are modified, manipulated or replaced (e.g. removal of parts, installation
of non-original Liebherr parts), both the crane permit and the manufacturer's warranty will become
void.
Leave installed original parts unchanged!
Do not remove original parts!
Use only original Liebherr spare parts!
Definition of directional data

Forward driving means driving with the driver’s cab on the front.
Reverse driving means driving with the tail lights of the chassis on the front.
Front, rear, right, left on the crane refer to the condition, that the driver’s cab and the boom point in
the same direction. Front is always in direction of the driver’s cab.
Front, rear, right, left in the driver’s cab refer to the crane chassis. The driver’s cab is always in the
front.
Front, rear, right, left in the crane operator’s cab refer to the superstructure. Front is always in
direction of the boom.
Optional
Customer-specific equipment is marked with *.
0.01 LIEBHERR 7
Contents
8 LIEBHERR
Contents
Contents
1.00 Description of crane 19
1.01 Terminology 20
1 Crane Components 21
2 Additional boom 23
1.02 Product description 24
1 Crane chassis 25
2 Crane superstructure 26
3 Additional equipment 27
1.03 Technical data 28
1 Dimensions 29
2 Stabilizers 29
3 Tires 30
4 Weights 30
5 Workplace-related emission value 30
6 Vibrations 31
7 Speeds 31
8 Rope diameter 32
9 Hoisting heights 32
2.00 Safety 43
2.01 Traffic regulations 44
1 Traffic regulations 45
2.02 Break-in instructions 46
1 Break-in instructions 47
2.03 Job planning 48
1 Planning crane operation 49
2.04 General safety technical guidelines 50
1 General 51
2 Emergency exit 55
3 Safety guidelines for ladders 57
LIEBHERR 9
Contents
4 Requirements of the crane operator 62
5 Selecting the location, illustrations 1 to 3 73
6 Slopes and excavations, illustrations 4 and 5 76
7 Permissible ground pressures 76
8 Supporting 81
9 Checking the safety measures 82
10 Crane operation with a load 83
11 Lifting of personnel 86
12 Grounding 87
13 Crane operation in case of thunderstorms 88
14 Welding work on the load 88
15 Safety instructions for external power supply (230 V AC) 88
16 Endangering air traffic 89
17 Joint lifting of a load by several cranes 90
18 Working in the vicinity of transmitters 93
19 Hand signals for guidance 95
20 Beaufort Wind chart 95
21 Consideration of wind conditions 96
22 Interruption of crane operation 98
23 Taking up crane operation again 98
24 Ending crane operation 99
25 Turning / driving in reverse 99
26 Parking the vehicle 99
2.05 Signs on the crane 101
1 Warning signs 103
2 Command and prohibition signs 109
3 Notice signs 113
2.06 Antifall guards on the crane 117
1 Antifall guards on the crane 119
2 Fastening points 119
3 Attachment points on folding jib 121
4 Railings on the crane superstructure 125
5 Cranes with luffing* cab 127
10 LIEBHERR
Contents
2.10 General safety technical notes for driving with dolly 128
1 Travel operation with dolly 129
3.00 Crane chassis operation 139
3.01 Operating and monitoring instruments on the crane chassis 140
1 Vehicle operating and control instruments 141
3.02 Turntable assembly 160
1 General checks before starting to drive 161
2 Work station - Driver's cab 167
3.03 Axle suspension system 172
1 General 173
2 Axle suspension system 175
3 Axle locking system 181
3.04 Travel operation 182
1 Crane driving conditions 183
2 Starting and stopping the engine 187
3 Driving 195
4 Differential locks 235
5 Steering 241
6 Towing 251
3.05 Crane at the job site 252
1 General 253
2 Support control unit 259
3 The “Support” program 273
4 Before leaving the work site 283
4.00 Operation of crane superstructure 285
4.01 Operating and monitoring instruments on the crane superstructure 286
1 Operating and control instruments 287
4.02 LICCON computer system 300
1 General 301
2 LICCON computer system boot up 303
3 Operating elements of the LICCON computer system 307
4 “Configuration” program 309
5 The “Operation” program 327
LIEBHERR 11
Contents
6 “Telescoping” program 375
7 “Control parameter” program 379
8 The “Working range limitation” program* 387
9 The “Support” program 389
10 The “Engine monitoring” program 405
11 LICCON computer system in stand-by mode 413
4.03 Crane start up and taking the crane out of service 416
1 Checks before starting up 417
2 Crane operator's cab workplace 421
3 Starting and stopping superstructure engine and chassis engine 429
4 LICCON computer system after engine start 439
4.04 Safety equipment 442
1 General 443
2 LICCON computer system 443
3 Safety devices on the crane 447
4 Safety systems 451
4.05 Crane operation 454
1 General 455
2 LICCON computer system 463
3 Luffing 465
4 Lifting / lowering 469
5 Turning 471
6 Telescoping 477
4.06 Rope reeving 488
1 Wire ropes and rope end connections 489
2 Reeving the hoist rope with the auxiliary reeving rope 491
3 Reeving the hook block in and out 495
4 Securing and removing the load hook* 501
5 Attaching / removing the hoist limit switch weight 505
6 Assembling / disassembling the wedge lock 509
7 Crane operation with auxiliary block* on the telescopic boom 511
8 Rope reeving 511
4.07 Counterweight 512
1 General 513
12 LIEBHERR
Contents
2 Assembly 519
3 Disassembly of the counterweight plates 523
4.08 Working with a load 528
1 Technical safety instructions for working with a load 529
2 Checks before starting to work with the crane 530
3 Crane movement - Telescoping 531
4 Taking on a load 533
5 Crane operation 537
4.12 Two hook operation 539
1 General 541
4.15 Reeving plans 546
1 Reeving plans 547
4.20 Procedure for shut off of crane movements 560
1 General 561
2 Instructions for resuming crane movements for cranes with CE mark 565
3 Instructions for resuming crane movements for cranes without CE mark 601
5.00 Equipment 637
5.01 Safety technical guidelines for assembly and disassembly 638
1 Checking the retaining elements 639
2 Rope pulleys 639
3 Checking the ropes 639
4 Inspection procedures 640
5 Dangerous conditions without shut off 642
6 Transporting components 642
7 Pneumatic springs for assembly support of components 643
8 Manual rope winches for assembly support of components 643
9 Weights 644
10 Guy rods 644
11 Exceeding the overload protection 647
12 Assembly / disassembly 649
13 Erection / take down 678
5.02 Folding jib - TK 680
1 General 681
LIEBHERR 13
Contents
2 Assembling the folding jib 691
3 Reeving in the hoist rope 715
4 Changing mechanical folding jib from 0° to 22.5° or 45° 717
5 Hydraulic connections 723
6 Electrical connections 729
7 Erection 735
8 Adjusting the folding jib angle of the hydraulic folding jib 737
9 Changing the mechanical folding jib from 22.5° or 45° to 0° 741
10 Unreeving the hoist rope 747
11 Removing the folding jib 749
5.09 Hoist gear 2 772
1 General 773
2 Assembly 773
3 Dismantling 775
5.10 Boom nose 776
1 General 777
2 Assembly 777
3 Dismantling 783
5.12 Auxiliary boom 786
1 General 787
2 Installing the auxiliary boom 787
3 Erection 803
4 Unreeving the hoist rope 805
5 Dismantling the auxiliary boom 807
5.19 Hook blocks 814
1 Minimum required hook block weight 815
2 Procedure in case of slack rope 818
3 Hook block overview 821
4 Installing the single blocks 823
5 Removing the single blocks 827
5.25 Telescopic boom extension 830
1 General 831
2 Assembly 833
3 Create electrical/hydraulic connections 835
14 LIEBHERR
Contents
4 Setting up 835
5 Dismantling 837
5.27 Erection and take-down charts 838
1 General 839
2 Setup and takedown chart for the T-operation 839
3 Setup and takedown chart for the TK/TNZK operation 839
4 Setup and takedown chart for the TVK/TVNZK operation 840
6.00 Additional equipment 841
6.01 Heater / engine pre-heating 842
1 Heating the driver's cab 843
2 Heating the crane operator's cab 859
6.04 Sliding beam monitoring 870
1 General 871
2 Support bases 871
3 Working with sliding beam monitoring 873
6.05 Emergency take-down 878
1 Emergency operation 879
6.07 Emergency operation of support 882
1 Emergency operation of support 883
7.00 Service and maintenance 887
7.01 Maintenance and service - General 888
1 General 889
2 Cleaning and care of the crane 890
3 Measures taken upon work interruption or transport 891
4 Maintenance work on the crane superstructure or boom 891
5 Maintenance and inspection guidelines 892
7.02 Maintenance intervals - Crane chassis 895
1 Crane chassis maintenance and inspection schedule 897
7.03 Maintanance intervals - Crane superstructure 905
1 Crane superstructure maintenance and inspection schedule 907
7.04 Maintenance guidelines - Crane chassis 916
1 Diesel engine 917
2 Automatic transmission 923
LIEBHERR 15
Contents
3 Transfer gear box 927
4 Hydraulic system 931
5 Compressed air and brake system air dryer 941
6 Tires / wheels 941
7 Axles 943
8 Wheel alignment 945
9 Tilting the driver's cab 947
10 Electrical system - lighting 947
7.05 Maintenance guidelines - Crane superstructure 950
1 Crane engine 951
2 Pump distributor gear 955
3 Hydraulic system 957
4 Central lubrication system 963
5 Slewing ring connection 971
6 Hoist gears 973
7 Slewing gear 977
8 Air dryer of the compressed air system of the crane superstructure 979
9 Electrical system - Lighting 979
10 Telescopic boom 981
7.06 Fill quantities, lubrication chart 982
1 Fill quantities 983
2 Lubrication schedule 987
7.07 Service fluids and lubricants 992
1 Service items and lubricants required for LIEBHERR cranes 993
7.15 Procedure in case of problems 1002
1 Procedure to follow in case of a problem 1003
2 Measures in clear problem cases 1007
3 Carry out error diagnostics 1019
4 Measures for defective components 1021
8.00 Inspections of cranes 1027
8.01 Periodic crane inspections 1028
1 General 1029
2 Inspection of carrying crane structures, especially steel structures 1030
16 LIEBHERR
Contents
3 Inspection of tires and disk wheels 1095
4 Inspecting the hoist and luffing winches 1097
5 Inspecting load hooks 1109
6 Inspecting the rope feed mechanics in the telescopic boom 1109
7 Inspection of locking system of telescopic boom 1111
8 Inspection of membrane accumulator 1111
9 Inspection of relapse cylinders 1111
10 Inspection of the safety controls on the relapse cylinders 1112
11 Inspecting the cable pulleys 1112
12 Inspecting the function of the overload protection 1112
13 Inspecting the roller ring connection 1112
14 Inspecting the mounting of the load bearing equipment 1112
15 Inspection of the tele extension with eccentric, illustration 1 1115
16 Inspection of change over pulleys, illustration 2 1115
17 Inspecting the oil and fuel reservoirs 1115
18 Inspection of the auxiliary reeving winch, towing winch and spare wheel winch 1115
19 Appendix 1116
8.04 Inspection of crane wire ropes 1126
1 Introduction 1127
2 Wire rope 1127
3 Operating behavior of steel ropes 1133
4 Condition of equipment that is functionally associated with the rope 1133
5 Rope inspection log 1133
6 Rope storage and marking 1133
7 Wire ropes and rope end connections 1133
8 Twisting caused by stretching in rotation-resistant ropes and its remedy 1137
9 Appendix 1 1141
10 Appendix 2 1143
11 Appendix 3 1145
12 Appendix 4 1145
8.07 Inspection of pneumatic brake system for disk brakes 1148
1 General 1149
2 Visual inspection 1149
LIEBHERR 17
Contents
3 Function and performance test 1149
4 Internal inspection of the wheel brake 1151
9.00 General notes 1155
9.02 Supplementary service work 1156
1 Checks before start up 1157
2 Repair and maintenance tasks 1157
3 Important service tasks 1157
4 Maintenance notes for replacement parts 1158
5 Recommendations for travel operation 1158
6 Disposal of fuels and lubricants 1158
7 Tires 1158
90.00 Appendix 1167
90.01 Foreword to appendix 1168
1 Preface 1171
90.05 Update confirmation 1172
1 Update confirmation 1173
Index 1175
18 LIEBHERR
1.00 Description of crane
LIEBHERR 19
026703-00 1.01 Terminology
B199858
20 LIEBHERR 1.01
1.01 Terminology 026703-00
1 Crane Components
1.1 Crane Chassis

1 5-axle chassis
2 Tyres
4 Drive motor
5 Cab
5 Sliding beams • with support rams
6 Support pads
1.2 Crane superstructure

10 Crane motor
11 Crane cab
12 Counterweight
13 Luffing cylinders • for telescopic boom adjustment
14 Winch 1
15 Winch 2*
16 Hoisting cable
17 Hook block
1.3 Telescopic boom (T)

20 Articulated piece
21 Telescopic part 1
1.01 LIEBHERR 21
026703-00 1.01 Terminology
B196240
22 LIEBHERR 1.01
1.01 Terminology 026703-00
2 Additional boom
2.1 Folding jib, type TK*

31 Adapter
33 Headpiece
34 Intermediate piece
2.2 Folding jib with extension (TVK)*

31 Adapter
33 Headpiece
35 Adjusting cylinder
2.3 Hydraulic adjustable folding jib with extension (TNZK)*

31 Adapter
33 Headpiece
2.4 Hydraulic adjustable folding jib with extension (TVNZK)*

31 Adapter
33 Headpiece
35 Extension
1.01 LIEBHERR 23
026688-00 1.02 Product description
B198140
24 LIEBHERR 1.02
1.02 Product description 026688-00
1 Crane chassis
1.1 Frame
In-house manufactured, weight-optimised, distortion-resistant box structure made from high-strength,
close-grained structural steel.
1.2 Supports
4-point support, fully hydraulically extendable horizontally and vertically.
Automatic support levelling.
Electronic slope indicator.
1.3 Motor
6-cylinder diesel, manufactured by Liebherr, model D 846 A7, water-cooled.
Performance: 370 KW at 1900 rpm
Maximum torque: 2355 Nm at 1200 - 1500 rpm
Exhaust emissions according to guidelines per 97/68/EC Stage 3 and EPA/CARB Tier 3.
Fuel tank: 490 l
1.4 Transmission
ZF 12-speed transmission system with automatic switching system AS-TRONIC.
ZF intarder attached directly to the transmission.
Two-stage transfer gearbox, with lockable distributor differential.
1.5 Axles
All 5 axles are welded and made from high-strength, close-grained structural steel.
All axles with steering.
Axles 2, 4 and 5 are planetary axles with differential locks.
1.6 Suspension
All axles with "Level-matic suspension" hydro-pneumatic suspension and hydraulically lockable.
1.7 Tires
10 tires.
Tire size: 385 / 95 R 25
1.8 Steering
ZF servocom power steering gear, dual circuit system with hydraulic servo mechanism and auxiliary
stand-by pump, powered from the axle.
The axles 3, 4 and 5 are steered electro-hydraulically, depending on the speed, and from 30 km/hr.,
the third and fourth axle are affixed to straight forward travel.
From 60 km/hr., the fifth axle is affixed for straight forward travel.
Steering in correspondence with EC-guideline 70/311/EEC.
1.02 LIEBHERR 25
026688-00 1.02 Product description
1.9 Brakes
Service brake: all-wheel power-assisted compressed air brake, dual-circuit system
All axles are equipped with disk brakes.
Handbrake: spring-loaded brake acting on the wheels of the second to fifth axle
Retarder: engine brake as exhaust flap retention strap brake with Liebherr auxiliary braking system
ZBS
Intarder on the gear box. Brakes conform to EU Council Directive 71/320/EEC.
1.10 Driver cab

Spacious cab made of steel, corrosion-resistant through cataphoretic E-coat, elastomerically
suspended and hydraulically damped.
Sound and heat insulating interior panelling according to EC-guideline, safety glass, operating and
control instruments, luxury equipment.
1.11 Electrical system

Modern data bus technology, 24 Volt DC, 2 batteries, each with 170 Ah.
Lighting system in accordance with German StVZO (Federal Motor Vehicle Safety Standards).
2 Crane superstructure
2.1 Frame
In-house manufactured, weight-optimised and distortion-resistant welded structure made from
high-strength, close-grained structural steel. A 3-row roller slewing ring is used as the connecting
element to the crane chassis, providing unlimited rotation.
2.2 Crane engine

4-cylinder diesel, manufactured by Liebherr, model D 934 L A6, water-cooled.
Performance: 180 KW at 1800 rpm
Maximum torque: 1140 Nm at 1500 rpm
Exhaust emissions according to guidelines per 97/68/EC Stage 3 and EPA/CARB Tier 3.
Fuel tank: 265 l
2.3 Crane drive

Diesel hydraulic with 5 axial piston adjustment pumps with servo control and power control, 1 dual
gear pump.
Hydraulic power system in a compact design is flanged directly onto the Diesel engine, complete drive
assembly encased for noise reduction.
2.4 Controls
Electronic control system from LICCON-system (PLC control). Two 4–way manual control levers,
self-centering. Infinitely variable control of all crane movements by adjusting the hydraulic pumps,
additional speed control when adjusting the diesel engine RPM.
2.5 Hoist gear

Axial piston adjusting motor.
Liebherr rope winch with built-in planetary gear and spring-loaded stop brake.
The hoist gear is powered in a closed oil circuit.
26 LIEBHERR 1.02
1.02 Product description 026688-00
2.6 Luffing gear

1 differential cylinder with safety check valves.
2.7 Slewing gear

Axial piston fixed displacement motor, planetary gear, spring-loaded stop brake.
2.8 Crane driver's cab

Steel construction, fully galvanized, powder-coated, with safety glass, operating and control elements,
luxury equipment.
Cab can be tilted backwards.
2.9 Safety equipment

LICCON overload system, test system, hoist limit switch, safety valves to prevent pipe and hose
breakage.
2.10 Telescopic boom

Dent and distortion-resistant design made from high-strength, close-grained structural steel with oval
boom section, 1 articulated piece and 5 telescopic sections. All telescopic sections are hydraulically
extendable independently of each other. Rapid-cycle telescoping system “Telematik”.
Boom length: 13.3m to 60m
2.11 Counterweight
74 t
2.12 Electrical system

Modern data bus technology, 24 Volt DC, 2 batteries, each with 170 Ah.
3 Additional equipment
3.1 Folding jib
12.2m to 36m long, can be attached below 0°, 22.5° or 45° in relation to telescopic boom.
Hydraulic cylinder* for adjusting the folding jib from 0° to 45°.
3.2 Telescopic boom extension

7 m long lattice component, of which 7 m are a higher coupling point for the folding jib.
3.3 Winch 2
For dual hook operation or during operations with folding jib if main hoist rope is to remain reeved.
3.4 Tires
10 tires
Tire size: 445 / 95 R 25 and 525 / 80 R 25
3.5 10 x 8 drive
The 2nd axle is also driven.
1.02 LIEBHERR 27
026689-03 1.03 Technical data
B199844
28 LIEBHERR 1.03
1.03 Technical data 026689-03
1 Dimensions
Tire size 385 / 95 R 25 445 / 95 R 25* 525 / 80 R 25*

A 3950 mm 4000 mm 4000 mm
B 3000 mm 3000 mm 3100 mm
C 2563 mm 2551 mm 2573 mm
D 3700 mm 3750 mm 3750 mm
E 2000 mm 2050 mm 2050 mm
F 15 ° 17 ° 17 °
G 12 ° 14 ° 14 °
H 18 ° 20 ° 20 °
I 14 ° 16 ° 16 °
2 Stabilizers
2.1 Dimensions support base
Support base Length Width

Retracted 8.89 m 2.70 m
Reduced 8.89 m 5.50 m
Wide 8.89 m 8.30 m
2.2 Dimensions support pad
Length Width
600 mm 600 mm
2.3 Support forces
Max. support force per support Front Rear

With nominal load 855 kN 1180 kN
1.03 LIEBHERR 29
3 Tires
3.1 Tires with “speed symbol E”
Tire size Wheel weight Tire pressure for driving on Tire pressure for driving
public roads with the equipment in place
385/95 R 25 260 kg 10 bar 10 bar
445/95 R 25* 320 kg 9 bar 10 bar
525/80 R 25* 375 kg 7 bar 8 bar
3.2 Tires with “speed symbol F”
Tire size Wheel weight Tire pressure for driving on Tire pressure for driving
public roads with the equipment in place
385/95 R 25 260 kg 9 bar 9 bar
445/95 R 25* 320 kg 9 bar 9 bar
4 Weights
4.1 Axle loads
Travel condition
See Crane operating instructions, chapter 3.04
4.2 Load tackle
Load Pulleys Strands Net weight

151.0 t 9 16 2.000 t
142.6 t 7 15 1.500 t
107.7 t 5 11 1.300 t
70.6 t 3 7 1.040 t
31.2 t 1 3 0.840 t
10.5 t - 1 0.500 t
5 Workplace-related emission value
30 LIEBHERR 1.03
Sound pressure level at nominal Stationary noise LpA

engine RPM
left ear right ear
Driver's cab, driver's side 74 dB(A) 74 dB(A)
Driver's cab, passenger side 74 dB(A)
Crane operator's cab 76 dB(A)
6 Vibrations
Vibrations transferred to the operator Value

Total vibration value to which the upper limbs are exposed not more than 2.5 m/s2
Effective value of weighted acceleration to which the entire body is not more than 0.5 m/s2
exposed to.
7 Speeds
7.1 Driving speeds with 385/95 R 25 tires
Speed Gear
1 2 3 4 5 6 7 8
Road gear 5.20 6.70 8.60 11.10 14.00 18.10 23.80 30.60
km/h km/h km/h km/h km/h km/h km/h km/h
Off-road gear 2.30 2.90 3.80 4.80 6.10 7.90 10.40 13.30
Speed Gear Maximum gradi-

ent
9 10 11 12 R1 R2
Road gear 39.40 50.50 64.20 75.00 5.60 7.2 48 %
km/h km/h km/h km/h km/h km/h
Off-road gear 17.20 22.00 28.00 35.80 2.40 3.10 > 60 %
1.03 LIEBHERR 31
7.2 Driving speeds with 445/95 R 25 and 525/80 R 25 tires
Speed Gear
1 2 3 4 5 6 7 8
Road gear 5.70 7.30 9.40 12.10 15.30 19.70 25.90 33.20
Off-road gear 2.50 3.20 4.10 5.30 6.70 8.60 11.30 14.50
Speed Gear Maximum gradi-

ent
9 10 11 12 R1 R2
Road gear 42.80 55.00 69.80 80.00 6.10 7.90 43 %
Off-road gear 18.70 23.90 30.40 39.00 2.70 3.40 56 %
7.3 Crane speeds
Drives infinitely variable Rope / rope length

Hoist gear 1 0 m/min - 130 m/min for single strand 23 mm /280 m
Hoist gear 2 0 m/min - 130 m/min for single strand 23 mm /280 m
Slewing gear 0 rpm - 1.3 rpm
Luffing gear approx 50 sec. 1 ° to 82 ° boom position
Telescoping approx. 580 sec. for boom length 13.2 m - 72 m
8 Rope diameter
Type of rope Rope diameter

Hoist rope 1 23 mm
Hoist rope 2 23 mm
9 Hoisting heights
32 LIEBHERR 1.03
blank page!
1.03 LIEBHERR 33
B196242 Telescopic boom (T)
34 LIEBHERR 1.03
B196466 Telescopic boom with folding jib (TK 22 m)
1.03 LIEBHERR 35
36 LIEBHERR 1.03
1.03 LIEBHERR 37
B196469 Telescopic boom with folding jib and extension (TVK 22 m )
38 LIEBHERR 1.03
B196470 Telescopic boom with folding jib and extension (TVK 26.2 m )
1.03 LIEBHERR 39
40 LIEBHERR 1.03
1.03 LIEBHERR 41
42 LIEBHERR
2.00 Safety
LIEBHERR 43
021178-06 2.01 Traffic regulations
B195219
44 LIEBHERR 2.01
2.01 Traffic regulations 021178-06
1 Traffic regulations
The crane is approved for road travel when used in accordance with regional traffic regulations.
The crane must be made to comply with the relevant local traffic regulations, before it is driven on
public streets, roads and other places.
The weights, axle loads and dimensions specified in the permits must be maintained and shall not be
exceeded by additionally loading the crane.
The technically feasible axle loads may be different from those permitted by local road traffic
regulations.
In countries where EEC specifications apply, axle loads greater than 12 t are not permitted for street
traffic.
All consequences for driving on roads with an axle load that exceeds 12 t rest with the crane operator.
DANGER
Exceeding the axle load and total weight increases the risk of accident!
Any increase in axle load and total weight reduces braking performance in direct proportion to the
excess weight.
Brake lining wear is greater and risk of brake overheating in higher. This condition exceeds the
specifications of the steering mechanism, operating and parking brakes and retarder!
It shortens the life of all components subjected to the increased axle load; e.g. brakes, tires, rims and
axles, as well as the entire drive, suspension and steering assemblies.
Do not exceed the specified axle load or total weight under any circumstances!
A hook block may only be transported at the front if:

– this is permitted by the current driving condition of the crane (see Chapter 3.04)
– it has been reeved at least four times
– and lashed using the eye provided on the front towing coupling
DANGER
Risk of accident if driver's field of vision is blocked!
Do not allow the hook block to impair the driver's field of vision when driving the crane on public
roads!
1.1 Boom nose*

If a boom nose is attached, it must be moved from the operating position to the transport position to
prevent field of vision impairment and must be secured in this position using bolts and safety springs.
1.2 National traffic regulations

Be sure to comply with all valid national traffic regulations when driving the crane!
The cab may not be occupied by passengers while driving the crane.
2.01 LIEBHERR 45
021617-05 2.02 Break-in instructions
B195219
46 LIEBHERR 2.02
2.02 Break-in instructions 021617-05
1 Break-in instructions
NOTICE
Risk of damaging while driving the crane.
It is absolutely essential to break-in the crane!
Please observe the following specifications:

1.) Continuously monitor temperature and oil pressure indicators while driving!
Stop immediately if there are any fault indications!
• Carry out the following maintenance work after the first 50 km and 100 km:
• Do not over-tighten the wheel nuts (maximum permissible torque= 600 Nm).
Make sure that wheel nuts are tight.
• Check engine water and oil levels.
• Check automatic or manual transmission and load transmission oil levels.
• Visually inspect engine, gearbox and axles for any leakage or loose components.
• Check that drive shaft is properly seated.
• Check that there are no other loose chassis components.
• Visually inspect tire condition and inflation.
1.1 Breaking in the brake linings

To achieve optimum braking performance, all new brake pads must be broken in by activating the
brakes.
WARNING
Risk of accident due to overloaded braking system!
The risk of accident increases when new brake pads are subjected to one or more braking operations
over extended periods of time or if the vehicle is forced to a stop by hard braking from maximum
speed several times.
Hard braking and continuous braking are not permitted!
For drum brakes, the following applies in addition:

Activate the brakes by pumping them at low to medium speed. Hard braking is not permitted. The
break-in distance generally depends on the vehicle capabilities, but a break-in distance of at least
500 km is advisable. The brake drum temperature must not exceed 200 °C during this phase. The
temperature rise resulting from each individual braking action should not exceed 15% of the maximum
value.
2.02 LIEBHERR 47
021674-00 2.03 Job planning
B195219
48 LIEBHERR 2.03
2.03 Job planning 021674-00
1 Planning crane operation

In addition to a perfectly working crane and a well-trained crew, crane operation planning is an
important principle of safe crane operation.
DANGER
Missing information increases the risk of accidents!
Crane operation may not be possible or improvisation can result if a crane operator does not have all
the required data.
A crane operator must have exact data before starting any work!
The crane operator must obtain or receive the necessary information in a timely fashion before driving
to the work site. In particular:
– type of crane operation
– work site (travel distance)
– route
– height and width clearance measurements
– electrical transmission lines (including voltages)
– space restrictions at the work site
– movement restrictions caused by buildings
– weight and dimensions of the load(s) to be hoisted
– required hoisting height and boom projection
– ground bearing capacity at the work site
Based on the above information, the crane operator must assemble the equipment required to
operate the crane:
– hook block / load hook
– auxiliary boom
– separate lifting accessories
– counterweight
– underlay materials for support pads
2.03 LIEBHERR 49
027297-10 2.04 General safety technical guidelines
B195219
50 LIEBHERR 2.04
2.04 General safety technical guidelines 027297-10
1 General
Note
The illustrations in this chapter are only examples. The illustrations may differ depending on the
crane model.
1.1 Danger zone of crane

The danger zone of the crane is made up of the areas which are accessed during crane operation by
the load or by movements of the crane or the crane components.
WARNING
Do not stay in danger zone!
Personnel within the danger zone cane be hit by falling loads or components!
Personnel in the danger zone can be caught by moving crane components or loads!
Fatal or severe injuries can be the result!
Warn any personnel within the danger zone with the warning device of the crane!
After the warning is issued, wait and ensure that no personnel remains within the danger zone!
If necessary, block off the danger zone with a safety distance of 0.5 m!
1.2 Exhaust systems and other heated crane components

WARNING
Danger of burns!
You can get severely burnt on the surfaces of hot components!
This applies especially to exhaust systems, the engines and the respective gears in the crane chassis
and in the crane superstructure!
Let the components cool off before touching them!
Proceed with special caution near heated crane components!
1.3 Movement on the crane

WARNING
Risk of accident!
No not step or place a load on surfaces, which are not approved, there is a danger of accidents!
Personnel can be severely injured or killed!
The crane can be damaged!
Observed the signage!
Replace damaged signs immediately!
WARNING
Danger of slipping / falling!
The traction of steps, walk ways and hand rails changes due to effects of the weather, such as
wetness, snow and frost!
Danger of slipping / falling!
Always move on the crane depending on the respective circumstances!
2.04 LIEBHERR 51
B109287
52 LIEBHERR 2.04
1.4 Crane operator's cab with retractable / extendable step
1.4.1 Entering / exiting of crane superstructure alignment length axis crane chassis
See illustration 1.
Before entering / exiting the crane operator's cab, the following prerequisites must be met:
– The crane superstructure is aligned in length axis of the crane chassis.
– The step under the crane operator's cab is moved in.
– The crane operator's cab with incline adjustment is in 0° position.
WARNING
Risk of falling!
If the crane superstructure is aligned in length axis of the crane chassis and the step is moved out,
see illustration 2, then there is a danger of falling when entering / exiting!
Set up a suitable access, such as a ladder or pedestal, to ensure safe entry into the crane
operator's cab!
When exiting the crane operator's cab in position crane superstructure in length axis crane
chassis, always move the step in completely!
1.4.2 Entering / exiting a swung crane superstructure

See illustration 3.
Before entering / exiting the crane operator's cab, the following prerequisites must be met:
– The crane superstructure is swung to the point where a safe access to the crane chassis is
ensured.
– For the crane operator's cab with incline adjustment, the crane operator's cab is in 0° position.
Note
Use extendable step!
The extended step allows comfortable entry into the crane operator's cab as well as safe exit from
the crane operator's cab to the crane chassis!
1.5 Crane operator's cab with incline adjustment

WARNING
Risk of falling!
If the crane operator's cab cannot be swung from an inclined position (for example 20° position) to the
0° position, for example due to a problem, then utmost caution must be used when entering / exiting
the crane operator's cab!
There is a danger of falling, personnel can be severely injured or killed!
For safety reasons, we recommend to take advantage of outside help!
If necessary, have appropriate pedestals or other suitable entry aids set up to ensure safe exit
from the crane operator's cab!
WARNING
Risk of accident!
If the door of the crane operator's cab is opened in inclined position, then the door can move back
suddenly!
Hands can be crushed or injured!
When the operator's cab is in inclined position, open the door carefully!
2.04 LIEBHERR 53
B109261
54 LIEBHERR 2.04
2 Emergency exit
2.1 Emergency exit - driver's cab

The driver's cab can be exited through the “left driver's door” or the “right passenger door”, see
illustration 1.
Note
Exit the driver's cab through the “left driver's door” or the “right passenger door”, see illustration 1:
Pull and open the door handle 10 on the “left driver's door” or the “right passenger door”.
2.2 Emergency exit - crane operator's cab

WARNING
Risk of falling!
If it is not possible to safely leave the crane operator's cab through the door or to reset the crane
operator's cab from inclined position to horizontal position, then the crane operator can fall from the
crane operator's cab during the emergency exit and be severely injured!
Be especially careful when exiting at emergency exit!
If the crane operator's cab cannot be exited safely, use outside aid!
In case of an emergency, if it is not possible to leave the crane operator's cab through the door, the
crane operator's cab can be exited through one of the following openings, depending on the model:
– Roof window, see illustration 2: Pull the pins 11 on the left and right and open the roof window
upward.
– Rear window, see illustration 2: Pull the pins 11 on the left and right and open the rear window
upward.
– Front window, see illustration 3: Unlock the left and right handles 12 and open the front window.
– Side window, see illustration 3: Unlock the top and bottom handles 12 and open the side window.
2.04 LIEBHERR 55
B109766
56 LIEBHERR 2.04
3 Safety guidelines for ladders
3.1 General
The ladders have been built according to the present level of technology and recognized safety
technical regulations. Despite that, during their use dangers to life and physical condition of the user
and / or third parties can occur. The ladders may only be used in a flawless technical condition and
according to their missions as well as with constant awareness of safety and dangers. Changes on
the structure may only be made with written approval of the manufacturer.
The ladders are exclusively designated for the entry and exit of personnel.
Any other use is not as intended.
The manufacturer is not liable for damages, which are caused by unintended use or improper usage.
WARNING
Risk of falling!
If the following safety guidelines are not observed, personnel can fall down and be killed or severely
injured!
Observe and adhere to the installation and safety guidelines for ladders!
Observe and adhere to the safety signs on the ladders!
Install and secure the ladders properly!
Do not use damaged ladders and replace them immediately!
Repairs on ladders may only be carried out by authorized expert workshops!
Before using the ladders, make sure that the following prerequisites are met:
– The ladders are hung and secured in the intended locations.
– The ladders are complete and not damaged (visual inspection).
– The legs of the ladders are not worn.
– Check the screws for tight seating and connection.
– The ladder may be subjected to a load of no more than one person or a maximum of 150 kg.
Before starting to drive / before transport, ensure that the following prerequisite is met:
– The ladders are tightly locked and secured in the intended transport retainers.
3.2 Maintenance
Note
Grease joints and pivot points on the ladders regularly and check them for easy movement, see
illustration 1 and illustration 2!
Remove any dirt on the ladders!
The ribbing on the rungs must be clear!
2.04 LIEBHERR 57
B109766
58 LIEBHERR 2.04
3.3 Safety signs on the ladders

Note
All safety signs on the ladders must be complete and always legible!
Sign Explanation
Read the operating instructions
Maximum load
Correct set up angle
Set up on level ground
Avoid leaning out to the side
Eliminate any contaminants on the ground
Set up on solid ground
2.04 LIEBHERR 59
Sign Explanation
Ladder overhang over the set up point
It is not permitted to step off to the side from the ladder
Only one person on every accessible bracket
Visual inspection of the ladder before use
Do not use the ladder as a bypass
Do not stand on the top step
Check the legs of the ladder
When transporting the ladder, be aware of any danger due to

overhead wires
Pay attention to correct set up direction
60 LIEBHERR 2.04
Sign Explanation
Face the ladder to go up or down the ladder
Before use, pay attention that the stepladder opens completely
Make sure the upper end of the ladder is placed correctly
Make sure that the safety strut engages
Maximum number of users on the ladder
Before use, make sure it is safety engaged
Correct access
When accessing the ladder, wear suitable shoes
Stepladders: Access the ladder to no more than the third step

from the top - without railing
2.04 LIEBHERR 61
Sign Explanation
Leaning ladders: Access to no more than the fourth step from the
top
Universal ladders: Access to no more than the fifth step from the
top
Access the ladder only when sober
Eliminate damaged ladders immediately
Total weight of the ladder
Illustration of ladder type with maximum length
Secure the upper / lower end of the ladder
4 Requirements of the crane operator

4.1 General
The crane operator's primary responsibility is to use and operate the crane in a manner that is safe for
both himself and others.
The following important safety guidelines will help you achieve this.
Many crane accidents are caused by incorrect crane operation.
62 LIEBHERR 2.04
WARNING
Danger due to operating error!
In the interest of both yourself and others, make sure you understand how your crane operates
and familiarize yourself with all the risks associated with the work to be done.
The main operating errors, which are made again and again while operating or driving a crane, are
as follows:
• Not paying careful attention while working, for example:
• Slewing too quickly
• Quick braking of the load
• Diagonal pulling
• Loose cable formations
– Overloading
– Driving too fast with a load, or setting up and loading on an uneven surface
– Attaching the load incorrectly
– Unsuitable operation; especially diagonal pulling, breaking away stuck loads
– Wind action on suspended loads
– Mistakes when driving on a road, for example:
• Overspeeding the engine when driving downhill
• Driving with turned on differential lock
– Crashing into bridges, roofs or high voltage wiring due to insufficient vertical clearance
– Inadequate support; support base, support under the support pads
– Incorrect assembly or disassembly of booms
In many cases, crane damage is caused by improper maintenance:
– Insufficient oil, grease or antifreeze
– Contamination
– Broken cable wires, defective tires, worn parts
– Emergency limit switches or load torque limiter (LMB) not operating properly
– Brake and clutch failure
– Hydraulic defects; for example cracked hoses
– Loose bolts
2.04 LIEBHERR 63
B107388
64 LIEBHERR 2.04
4.2 Personal protective equipment

WARNING
Danger of accidents or falling!
If protective devices are not worn, the crane operator or the auxiliary personnel can be killed or
severely injured!
Any overhead work, where there is a danger of falling must be carried out with suitable aids!
If fall arresters are available, then they must be used!
If work cannot be carried out using these aids or from the ground, the crane operator and the
assembly personnel must be protected from falling using approved fall arrest systems!
Only approved fall arrest systems (catch belt, connectors) may be used! These fall arrest
systems must meet the standards EN 354, EN 358, EN 360, EN 361, EN 362, EN 363 and
EN 365 or national regulations.
No fall cushioning devices may be used due to low, possible falling height.
The operating instructions of the manufacturer of the fall arrest systems must be observed and
adhered to!
Check regularly to make sure that the legibility of the product identification marking is ensured.
The crane operating company must provide personal protection equipment to the crane operator
and all auxiliary personnel!
The crane operating company must ensure that the crane operator and auxiliary staff wear
personal protection equipment!
The crane operator and auxiliary personnel are obligated to carry personal protection equipment
along and to wear them!
Replace defective or damaged personal protective equipment!
Personal protection equipment include the following equipment:

– Hard hat Protection from falling parts at assembly and disassembly Hitting the head at assembly
and disassembly of lattice mast equipment
– Safety gloves: As a rule, when working with cables, penetration safe safety gloves must be used.
– Fall arrest systems ( catch belt 1, connectors 2 for retaining systems and work place positioning)
to protect against the danger of falling
– Safety shoes: Protection from falling parts at assembly and disassembly
– Warning apparel
WARNING
High risk of accident!
Even personal protective equipment does not provide 100% protection!
A helmet can protect against small falling objects, but not against falling loads.
Personnel can nonetheless be killed or seriously injured!
Always remain aware of your surroundings and behave in a safe manner!
WARNING
Risk of accident!
If the following instructions or measures are not carried out, personnel can be killed or severely
injured!
A plan for rescue actions, taking all possible emergencies into account, must be on hand!
The following points can endanger the safe function of the personal protective equipment: For
example extreme temperatures, routing of connecting devices, routing over or around sharp
edges, chemical influences, electrical effects, cuts, abrasion, climatic influences or swing
movements during falls!
For that reason, appropriate safety preparations must be made!
2.04 LIEBHERR 65
WARNING
Danger of accidents due to fall subjected fall arrest systems!
If fall subjected fall arrest systems are not replaced after a fall, then the fall arrest systems may fail in
case of a new fall and personnel can be severely injured or killed!
Replace fall subjected fall arrest systems immediately!
WARNING
Important for the safety of the user!
If the personal protective equipment is subsequently sold into another country, the seller must
provide the instructions for use, maintenance, regular inspections and upkeep in the language of
the other country.
4.2.1 Documentation
Note
The crane driver, who employs the user, is responsible for the creation of documentation and
entry of the required data.
The following charts must be filled out after the respective inspections.
Documentation of personal protective equipment

Product:
Type and model / Identifica- Commercial name Identification number
tion
Manufacturer Address Phone and fax number, email

and internet page
Year of manufacture / expira- Purchase date Date of first use

tion date
Other significant data , such as number of document
66 LIEBHERR 2.04
Procedure of regular inspections and repairs of personal protective equipment

Date Reason of pro- Damage found, Name and signa- Date of next reg-
cess (regular in- repairs made and ture of expert ular inspection
spection or re- other significant personnel
pair) data
4.2.2 Identification
Every personal protective equipment or other equipment must be marked clearly and permanently in
the language of the user country. The identification must include at least the following data.
Manufacturer:
Product description:
Type and model / Identifica- Serial number: EN Standard(s)
tion:
Observe the warning notes and instructions!
4.3 Work on the crane superstructure or boom

WARNING
Risk of falling!
During work on the crane superstructure of boom, personnel must be secured with appropriate safety
measures to prevent them from falling! If this is not observed, working personnel can fall and be killed
or severely injured!
For all work on the crane where there is a danger of falling, suitable safety measures must be
taken!
The crane superstructure or boom may not be accessed without suitable aids!
Suitable aids are, for example: Lifting platforms, scaffoldings, ladders, assembly platforms,
auxiliary crane.
2.04 LIEBHERR 67
If railing are present on the crane superstructure, then they must be swung into operating position
and secured for all work, see crane operating instructions, chapter 2.06!
Only step on such aids with clean shoes!
Keep aids clean and free of snow and ice!
If the work cannot be carried out with such aids nor from the ground, then the assembly personnel
must secure themselves with approved catch systems to avoid falling, see section “Personal
protective equipment”!
It is prohibited to step on the driver's cab or cab roof and specially marked surfaces, see Crane
operating instructions, chapter 2.05!
4.4 Obligations of the crane operator

1.) Before starting to work, the crane operator must check the brake function and the emergency
shut off devices. He must monitor the condition of the crane for obvious defects. On wireless
controlled cranes, he must check the assignment of control unit and crane.
2.) The crane operator must cease crane operation in case of defects, which would endanger the
safety.
3.) The crane operator must report all defects on the crane to the appropriate supervisor, also to his
replacement in case of crane change.
4.) The crane operator must make sure that:
• All control devices are set to neutral or idle position before release of the energy supply to the
drive components.
• The control devices are set to neutral or idle position and the energy supply is shut off before
leaving the control platform.
• When taking down the control unit for wireless control, it is secured to prevent unauthorized
operation.
5.) The crane operator must ensure that cranes subjected to wind are not operated past the limits
which were set by the crane manufacturer, and that the boom is taken down at least when the
critical wind speeds for the crane are reached and at the end of the work.
6.) The crane operator must monitor the load at all crane movements or the load tackle devices
when moving the crane without a load, if they could cause a dangerous situation. If observation is
not possible, then the crane operator may move the crane only with the aid of a guide.
7.) The crane operator must give warning signs when necessary.
8.) The crane operator may not move loads over personnel.
9.) Any loads attached by hand may only be moved by the crane operator after he received a clear
sign from the person who attached the load, the guide or any other responsible party which was
assigned to that task by the contractor. If signals must be used to communicate with the crane
operator, then they must be agreed upon before use between the responsible party and the crane
operator. If the crane operator determines that the loads are not properly attached, then he may
not move them.
10.) As long as a load is suspended on the crane, the crane operator must keep the control devices
within reach. This does not apply for towing of vehicles with towing cranes.
11.) The crane operator may not run up to end positions operationally, if they are limited by the
emergency limit switches.
12.) After a load moment limiter was triggered, the crane operator may not take on an overload by
pulling in / raising the boom.
13.) The crane operator may not bypass the overload protection to increase the hoisting power of the
crane.
68 LIEBHERR 2.04
blank page!
2.04 LIEBHERR 69
B104101 Example for crawler crane with telescopic boom
70 LIEBHERR 2.04
B104102 Example for crawler crane with lattice mast boom
2.04 LIEBHERR 71
B104103 Example for mobile cranes
72 LIEBHERR 2.04
5 Selecting the location, illustrations 1 to 3

It is very important to choose an appropriate location for crane operation in order to minimize safety
risks.
DANGER
Risk of accidents due to ground with insufficient load bearing capacity!
If the crane is supported or driven on ground with insufficient load bearing capacity, then the crane
can topple over and kill personnel!
Only support or drive the crane on ground with the required load-bearing capacity!
Act responsibly when planning and selecting the crane location and route.
Note the following points!
When selecting the location for the crane, observe the following:
1.) Select the placement location in such a way that crane movements can be carried out without
collision, and that the outrigger supports can be extended to the support base stipulated in the
load charts.
Make sure that no personnel is injured or killed!
Always keep a safety distance of 0.5 m. If this is not possible, secure the danger zone.
2.) On mobile cranes:
Support the crane correctly and support the support pads according to the load bearing capacity
of the ground on the placement location.
3.) Keep a safety distance to basements or similar.
4.) Keep a safety distance to slopes or similar.
5.) Keep the radius to as low as possible.
6.) Select the correct boom length to the load case.
7.) Angular pull is prohibited!
8.) Select the correct reeving of the hoist rope to the load case.
9.) Bear in mind the weight and the wind exposure surface of the load.
10.) Select tackle according to the weight of the load, the type of attachment and the incline angle.
11.) Keep sufficient distance to electrical overhead wiring.
2.04 LIEBHERR 73
B108387 Example for crawler cranes
74 LIEBHERR 2.04
B108388 Example for mobile cranes
2.04 LIEBHERR 75
6 Slopes and excavations, illustrations 4 and 5

The crane may not be set up too close to slopes or excavations. Maintain adequate safety
distance A and safety distance B in accordance with the type of soil.
WARNING
The crane can topple over!
The edge of the slope or excavation can break in if safety distance A or safety distance B is too small.
If the edge of the slope or excavation breaks in, the crane can topple over and kill personnel!
Always maintain the required safety distance A and safety distance B!
Abbreviation Term
A Distance to bottom of excavation
B Distance to excavation
7 Permissible ground pressures
Permissible ground pressures

Soil type [N/cm2]
1. Organic ground:
Peat, sludge, muck 0
2. Uncompacted fill:
Construction debris 0 to 10
3. Non-cohesive ground:
Sand, gravel, rocks and mix 20
4. Cohesive soil:
a) Clayed silt, mixed with topsoil 12
b) Silt, consisting of poor clay and coarse clay 13
c) Plastic clay, consisting of potter's clay and fill
Stiff 9
Semi-solid 14
Solid 20
d) Mixed granular ground, clay to sand, gravel and rocky areas
Stiff 15
Semi-solid 22
Solid 33
5. Rock in evenly solid condition:
76 LIEBHERR 2.04
Permissible ground pressures

Soil type [N/cm2]
a) Brittle, with traces of decomposition 150
b) Not brittle 400
If there is any doubt about the load bearing capability of the ground at the site, soil tests should be
carried out by specialists using, for example, a penetrometer.
7.1 Permitted ground pressure for crawler cranes

During crane operation, significant forces are transferred to the ground. The ground must be able to
safely withstand the pressure. If the crawler area is inadequate, then it must be supported from below
according to the load bearing capacity of the ground.
WARNING
If the crane is not properly supported, the crane can topple over and fatally injure personnel!
The foundation support must be large enough for the ground conditions and constructed from solid
materials, such as wood or steel plates!
7.2 Permitted ground pressure for mobile cranes

When the crane is supported, the support cylinders transmit significant forces to the ground.
The ground must be able to safely withstand this pressure. If the support pad area is inadequate, then
it must be supported from below according to the load bearing capacity of the ground.
The required support area can be calculated from the load bearing capacity of the ground and the
crane support force.
Note
Consider that the support force, due to the counterweight, can be higher without a load than with
a load.
WARNING
If the crane is not properly supported, the crane can topple over and fatally injure personnel!
Only strong materials may be used for the support pad bases; for example properly dimensioned
wooden timbers!
In order to ensure that pressure is evenly distributed over the base surface, the support pads must
be positioned in the center of the support base!
Note
The following are general calculation examples. The values are used only to explain the
calculation steps. The crane specific values are in chapter 1.03 of the crane operating instructions.
2.04 LIEBHERR 77
Example: Calculation of specific support pressure

Maximum support force according to crane operating instructions, 720000 N
chapter 1.03 for example: 720 kN
Surface of square support plate with 550 mm side length according to 3025 cm2
chapter 1.03, for example: 302500 mm2
80 % as carrying surface of support plate: 302500 mm2 x 0.8 = 242000 2420 cm2
mm2
Specific support pressure = Support force / surface support plate 720000 N / 2420 cm2 =
297.52 N/cm2
Specific support pressure: 298 N/cm2
The value of the specific support pressure is far above the permissible ground pressure for all types of
granular soil. If this crane is utilized on bedrock, type of ground gravel, permissible ground pressure
20 N/cm2 , then the support surface must be increased.
Example: Calculation of required support surface

Maximum support force according to crane operating instructions, 720000 N
chapter 1.03 for example: 720 kN
Permissible ground pressure, for example: 20 N/cm2 20 N/cm2
Required support surface = Support force / permissible ground pressure 720000 N / 20 N/cm2 =
36000 cm2
Required support surface: 36000 cm2 = 3.6 m2
The surface of the support for each support plate must be at least 3.6 m2 .
Note
The corresponding support forces can be determined with the crane job planer.
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2.04 LIEBHERR 79
B180001 General example
80 LIEBHERR 2.04
8 Supporting
DANGER
When actuating the supports with attached load and / or at loaded derrick ballast guying, the incline
and the force conditions of the entire boom system change!
There is no shut off by the LICCON overload system!
When a load is suspended, it is prohibited to actuate the support!
When the derrick ballast guying is loaded, it is prohibited to actuate the support!
It is absolutely essential that the crane be supported exactly in accordance with the load charts to
ensure safe operation.
The match of the sliding beams placement surfaces must be observed to ensure proper force transfer
between the sliding beams.
The crane may only be supported in these extension conditions.
WARNING
Danger of tipping over!
f only the load side sliding beams are extended, the crane can tip over when turning or setting down
the load!
Move all 4 sliding beams and support cylinders out according to the data in the load chart!
In intermediate positions between the support bases supporting is prohibited!
Pin sliding beams to support base according to the load chart!
Fully pin in and secure the pins!
WARNING
Risk of tipping the crane due to incorrectly extending the sliding beams!
The load suspended on the hook causes tension and deformation of the hoist rope and telescopic
boom, the same applies to lattice jibs and guy ropes. If the load is dropped from the tackle cables or if
the tackle or hoist rope breaks in this situation, a sudden relief occurs. The boom snaps back quickly.
This can cause the crane to topple over.
Despite previous assumption, it might become necessary to swing the load to the opposite side. This
can cause the crane to topple over.
When turning from the vehicle longitudinal direction, the crane can topple over due to the boom or
counterweight momentum.
It is imperative that all 4 sliding beams and support cylinders be extended according to the data in
the load chart!
2.04 LIEBHERR 81
8.1 Crane alignment

In addition to the proper foundation for the supports, the horizontal alignment of the crane is of utmost
importance for safe crane operation.
DANGER
The crane may topple if it leans!
If the crane is positioned at an incline, and if the boom is turned towards the slope, then the boom
radius is increased as a result!
It is possible that the slewing gear can no longer hold the crane superstructure and, in extreme cases,
the crane can topple over!
It is imperative to align the crane horizontally before starting crane operation!
If the horizontal alignment of the crane has to be readjusted:
Set the load down on the ground before readjusting the crane!
Example: At a boom length of 50 m, a side incline of the crane by only 5° at a radius of 10 m causes
an increase of the radius of a = 4 m.
9 Checking the safety measures

– The placement location has been selected in such a way that the crane can be operated with the
least possible boom projection radius.
– The load bearing capacity of the ground is adequate.
– There is sufficient distance to excavations and slopes.
– It has been ensured that there are no live electrical wires within the working range of the crane.
– There are no obstacles which will hinder required crane movements.
– The crane is horizontally aligned.
– On mobile cranes:
• The axle suspension is blocked.
• All four sliding beams and support cylinders have been extended according to the support
base given in the load chart.
• The sliding beams are secured with pins to prevent them from moving.
• The support plates are pinned and secured in the operating position.
• The axles are relieved, which means the tires do not touch the ground.
82 LIEBHERR 2.04
10 Crane operation with a load

WARNING
If the crane is in condition which is not operationally safe, the crane can topple over or crane
components can fall down!
Before starting to work, the crane operator must ensure that the crane is in operationally safe
condition!
If safe crane operation cannot be ensured by the crane operator, then crane operation is
prohibited until an operationally safe condition for the crane is established!
Safety devices, for example: Load moment limiter, hoist limit switch, brakes must be fully
functioning, otherwise crane operation is prohibited!
Make sure that the following prerequisites are met:

– The load moment limiter must be adjusted according to the current crane configuration.
– The loads given in the load chart may not be exceeded.
– The crane load may never exceed those specified in the load charts.
– The weight, center of gravity and dimensions of the load to be lifted must be known.
– Load carriers, lifting equipment and tackle must be in accordance with specified requirements.
Note
It must be observed, that the weight of the hook block and the weight of the tackle must be
subtracted from the load given in the load chart, see the following chart!
Example:
Maximum permissible load according to chart 30,000 t
Weight of the hook block 350 kg - 0.350 t
Weight of the tackle rope 50 kg - 0.050 t
Actual load capacity of the crane = 29.600 t
The weight of the load to be lifted, in this example, may not exceed 29.6 t .
10.1 Counterweight
The counterweight required depends on the weight of the load to be lifted and the radius required for
work. The deciding factor for the selection of the counterweight is the data in the corresponding load
chart.
WARNING
If the counterweight is not attached in accordance with the load chart, the crane can topple over and
fatally injure personnel!
Install the counterweight in accordance with the load chart!
2.04 LIEBHERR 83
10.2 Hoist gear, hoist rope

The lifting capability of the crane depends on the pull force of the hoist gear and the number of
possible hoist rope reevings. When working with a single strand, the crane can only lift as much of a
load as the hoist gear is able to pull.
If the load to be lifted is heavier than the pull force if the hoist gear, then the hoist rope must be reeved
as needed according to the principle of a pulley between the pulley head on the boom and the hook
block.
When reeving, carefully observe the load chart specifications and the operating manual instructions.
WARNING
Hoist rope failure!
If the maximum pull force of the hoisting gear is exceeded, the hoist rope can break or the hoisting
gear can be damaged!
The load can fall and kill personnel!
Never exceed the rated pull force of the hoist gear!
84 LIEBHERR 2.04
10.3 Crane operation

DANGER
There is a high risk of accidents should the following points not be observed!
It is imperative to comply with the following instructions.
High accident risk if:

1.) The load torque limiter is not set to the actual configuration status of the crane, and as a result,
cannot fullfil its function as a safety device.
2.) The load torque limiter is defective or put out of operation.
3.) The hoist limit switches are defective or turned off.
4.) On crawler cranes:
The angle sensor and the force test brackets are not functioning.
The sliding beams of the hydraulic supports are not extended to the points specified in the load
chart.
6.) On crawler cranes:
The crawlers are not supported with stable base material sufficiently large for the soil conditions.
The support plates are not supported with stable base materials sufficiently large for the ground
conditions.
8.) If the load is pulled at an angle.
Angular pulling to the side is particularly dangerous, because the boom has only minimal lateral
moment of resistance.
It is prohibited to pull a load at an angle.
9.) An excessive load is attached to the hook during disassembly work, which then hangs freely on
the crane when it is detached.
10.) If loads which have become stuck are pulled free with the hook block.
Even if the weight of the load which is stuck is no greater than the permissible lifting load, the
crane may topple over backwards if the load is suddenly freed since the tension created in the
boom can cause it to jerk back violently.
11.) Work is carried out in strong winds.
Refer to the data given in the load chart.
12.) The crane is not aligned horizontally and the load is slewed toward the slope.
13.) The hook load begins swinging because the crane operator has not properly controlled the
movements.
14.) The loads and boom projection radii contained in the load charts are exceeded.
15.) When working in the vicinity of power cables, these are not isolated by electricity engineers or if
the hazardous area is not covered of fenced off.
If it is not possible to take such measures, a sufficient safety clearance must be maintained:
Rated voltage Minimum distance

Up to 1 kV 1m
More than 1 kV to 110 kV 3m
If rated voltage is unknown 5m
2.04 LIEBHERR 85
WARNING
Danger of current transfer!
If, despite all precautions having been taken, a flashover occurs, carry out the following procedure:
Keep calm!
Do not leave the crane operator's cab!
Warn those around the crane not to move and not to touch the crane!
Move the crane away from the danger area!
11 Lifting of personnel
11.1 Generally valid instructions:
Note
The destined use of the crane is lifting of loads!
Lifting of personnel is not considered to be destined use of the crane!
The national laws and regulations for lifting personnel must be adhered to!
DANGER
When lifting personnel, the dangers of accidents and falling are significantly increased. Accidents
which occur when lifting personnel often result in severe injuries or even death!
The company, the supervisor, the crane operator and auxiliary personnel must proceed especially
carefully and safety conscious!
The following warning notes and safety regulations must be strictly observed!
Lifting of persons with personal lifting devices is only permitted for the assembly, the use and the
removal, if the user can prove that reaching the work area by conventional means, for example:
Via elevator, ladder, steps, lift, aerial platform or scaffolding is dangerous or due to the structural
design of the project or the work place condition is not possible!
Lifting of persons is only permitted with personal lifting devices, which have been designed for
lifting personnel and which were tested and approved!
When lifting personnel, the total load, including personal lifting devices, load lifting devices and
load hook may only be 50% of the nominal load for the respective condition of the valid load
charts!
The reeving must be handled in such a way that the rope pull with personal lifting devices, load
lifting devices and load hook does not exceed 50% of the maximum rope pull!
The crane operator many not leave the crane operator's cab while lifting personnel with the crane!
The lifting person must be in radio contact with the crane operator!
The rescue of person(s) in the personal lifting device must be planned in advance in case it is
necessary in an emergency!
As long as person are lifted, the crane may not be used for other purposes!
The job planning for crane operation, where personnel is to be lifted must be made especially
carefully!
Check the load bearing capacity of the ground especially carefully!
Lifting personnel may only be carried out by authorized and trained expert personnel!
Unauthorized persons must remain outside the danger zone!
Carry out all crane movements especially carefully and smoothly!
The persons to be moved must secure themselves with personal protective equipment (for
example safety harnesses) to protect them from falling from the movement devices!
86 LIEBHERR 2.04
Do not step on lifted loads or lifted tackle!

The crane operator may not move personnel with the load or the load tackle!
Before using the safety devices of the crane, check them for proper function! This applies
especially for the hoist limit switch and the load moment limitations! But all other crane functions
must also be in proper condition!
The crane must be equipped in such a way that personnel can exit the personnel lifting device
without danger in case of a power failure or if the control of the personnel lifting device cannot be
returned to the initial position!
The national laws and regulations for lifting personnel must be adhered to!
11.2 In addition, the following applies for Germany:

Note
In Germany, lifting of personnel under observation of the safety regulations for “liftable personnel
lifting devices” of the trade associations (Berufsgenossenschaften) BGR 159 is permissible!
DANGER
The following warning notes and safety regulations must be strictly observed!
Moving personnel and personnel lifting devices and working with these personnel lifting devices is
approved and monitored by the national occupational heath and safety agencies, in Germany the
trade association (Berufsgenossenschaft)!
Observe the safety regulations and guidelines of the national occupational health and safety
agencies!
Additional obligations of the company:

– Report the operation of the lifting device to the appropriate trade association.
– Determination of supervisor.
– The operator of the lifting device must be familiar with the tasks.
– The contractor may not assign other tasks to the lifting device operator and the guide while
personnel is being lifted.
– The contractor must make lifting devices with sufficient load carrying capacity available.
– The contractor must provide personal protective equipment (such as safety harnesses).
– Liftable personnel lifting devices must be inspected before the initial use and after significant
changes by an expert before putting them back into service:
• Carry out trial runs in the present of the supervisor.
• Regular inspections at least once a year.
• Record and save proof of inspections.
12 Grounding
12.1 Grounding the crane
WARNING
Danger of fatal injury due to electric shock!
There is a risk of electrical shock, if the crane is not properly grounded.
Properly ground the crane!
Make sure that there is a potential equalization between the crane and the ground!
The crane must be grounded before operation:

– Near transmitters (radio and TV transmitters, radio stations, etc.)
– Near high frequency switching stations
– In case of severe possibility of thunderstorms or potential thunderstorms
2.04 LIEBHERR 87
The crane can become electrostatically charged, especially if the crane is equipped with synthetic
support pads or if the support plates are placed on insulating materials (such as wooden planks).
12.2 Grounding the load

WARNING
There is a risk of electrical shock, if the load is not properly grounded!
Properly ground the load!
Make sure that there is a potential equalization between the load and the ground!
The load must be grounded before operation:

– Near transmitters (radio and TV transmitters, radio stations, etc.)
– Near high frequency switching stations
– In case of severe possibility of thunderstorms or potential thunderstorms
The load can become electrostatically charged, even if the crane is grounded. This applies in
particular if a hook block with pulleys made of synthetic material and non-conductive fastening
equipment (for example plastic or manila ropes) are used.
13 Crane operation in case of thunderstorms

In weather conditions, which can include lightning:
– Stop work on the crane.
– If possible, place the load down.
– If possible, telescope the boom in or put it down and bring it into a safe condition.
If this is not possible, the crane operator's cab must remain occupied to keep the crane and the load
always under control.
WARNING
Danger of accidents due to lightning strikes!
Make sure that there are no persons near the immediate area of the crane.
14 Welding work on the load

Note
The load must also be grounded.
In case of welding work on the load, the screw clamp of the welding unit must be attached on the
welding piece to avoid current flow via hoist rope, crane superstructure or crane chassis.
15 Safety instructions for external power supply (230 V

AC)
88 LIEBHERR 2.04
A potential hazard exists when supplying a crane with external power from a low voltage distribution
system (230 V AC).
In particular, the following conditions pose an electrical hazard: touching a crane with open grounds
(caused by the mechanical stress on flexible supply cables or the service connection), loose terminal
connections, high wire or contact resistance, mixed up conductors, defective or missing protective
equipment (fault interrupters) in combination with a body contact on the crane.
WARNING
Danger of fatal injury if the body conducts current!
Water and / or defective devices can cause hazardous stray voltages when touched. Subject to lethal
currents.
The external supply cable must be in good working order!
Make sure that the external flexible supply line is in good working order.
Where applicable, we recommend the use of an isolation transformer.
16 Endangering air traffic

When working with crane, heights are reached which could endanger air traffic. This applies
especially to areas near airports.
WARNING
Endangering air traffic!
If no protective measures are taken, this can result in endangerment to air traffic!
Get the approval from agency responsible for air traffic!
Assemble the airplane warning light on the boom head and turn it on!
2.04 LIEBHERR 89
17 Joint lifting of a load by several cranes

If a load is to be lifted by several cranes, the procedure must be previously determined by the
contractor or his representatives, and must be carried out in the presence of a supervisor assigned by
the contractor.
Proceed with particular care in the following cases:
– The part to be lifted has no even shape.
– Dynamic influences are to be taken into account when the load is freed.
Note
In the event of differing load-bearing capacities of the cranes, attach the loads in such a way as
each crane is only loaded with its own permissible load-bearing capacity.
WARNING
High risk of accident during dual-lifting!
When lifting or lowering the load, the individual cranes can be overloaded and topple over!
Personnel can be killed or seriously injured!
Only load the individual cranes with their individually permissible load capacities!
Angular pull is prohibited!
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2.04 LIEBHERR 91
B189640 General example
92 LIEBHERR 2.04
18 Working in the vicinity of transmitters

Strong electromagnetic fields are likely to be present if the construction site is close to a transmitter.
Electromagnetic fields can expose people and objects to direct and indirect risks, such as:
– Effect on human organs due to temperature increase
– Danger of burns or inflammation due to temperature increase
– Spark or electric arc formation
DANGER
Risk due to electromagnetic fields!
Before operating a crane in the vicinity of transmitters, be sure to consult with LIEBHERR!
Also consult a high frequency specialist!
High frequency (HF) radiation from a transmitter requires supplementary work safety protection and
special environmental specifications for crane operators and personnel:
1.) Each crane must be “fully” grounded. Check visually or with a simple tester to ensure that ladder,
cab and cable pulleys are grounded.
2.) All personnel working on the crane or with large metal objects must protect themselves from
burns by wearing non-conductive synthetic gloves and suitable clothing while working.
3.) There is no need to panic if you feel your hand warm up. Always work under the assumption that
the respective workpiece, structural steel member or support is “hot”.
4.) The temperature of objects affected by high frequency radiation depends on their “size”. Cranes,
carriers and coverings, for example, are “hotter”.
5.) Contact with other crane loads is not permitted when operating the crane (arcing). Since defects
caused by burns considerably reduce cable carrying capacity, any such occurrences must be
reported immediately to the machinery supervisor so that the cables can be inspected.
6.) An insulator 1 is required at all times between the crane load hook and tackle. It is strictly
prohibited to remove this insulator 1.
7.) Do not touch the cables above the insulator 1.
8.) Loads that are attached to the crane may not be touched by any unprotected parts of the body
after the load has been lifted or set down.
9.) Do not work with a bare upper torso or in short pants, this is prohibited.
10.) To minimize absorption of high-frequency radiation, larger loads should be transported
horizontally if possible.
11.) Loads must be grounded, or additional insulation used (rubber material between the object and
gloves) when manual work is required.
12.) Use a suitable measuring instrument to check the “temperature” of the workpiece.
For example, if 500 V can be measured on a tool at a distance of 1 cm - 2 cm, then the tool may
not be touched with bare hands.
The greater the distance, the higher is the voltage on the object:
At 10 cm distance, approx. 600 V are present, at 30 cm distance approx. 2000 V are present.
13.) When refueling the crane, it must be ensured that no sparks are created within a radius of 6 m,
neither by handling larger metallic parts nor by other work.
14.) To avoid secondary accidents, use personal protective equipment when working on components
that are high off the ground.
15.) Any accidents and unexpected events must immediately be reported to the local construction
supervisor and the safety engineer.
2.04 LIEBHERR 93
B180003
94 LIEBHERR 2.04
19 Hand signals for guidance

For all crane movements, the crane operator must always keep the load, as well as the crane hook or
loading equipment when the crane is not loaded, in his field of vision.
WARNING
Risk of accident due to standing under swaying loads!
Constantly keep loads in sight!
Standing under swaying loads is not permissible!
If this is not possible, the crane operator may only operate the crane if he is signed by an assigned
guide.
The operator may be guided by hand signals or a two-way radio. It must be ensured that there are no
misunderstandings.
WARNING
Danger of accident caused by misunderstood hand signals!
Hand signals must be mutually agreed upon and clearly executed!
We recommend using the hand signals described on the previous page.

In any case, national regulations must be observed when abroad.
Hand signal explanation:
Luff the boom up 1
Luff the boom down 2
Lift the load slowly 3
Lower the load slowly 4
Luff the boom up slowly 5
Luff the boom down slowly 6
Luff the boom up and hold the load 7
Luff the boom down and hold the load 8
Telescope the boom out 9
Telescope the boom in 10
Luff the boom up and lower the load 11
Luff the boom and lift the load 12
Lift the load 13
Lower the load 14
Turn the load in this direction 15
Set everything down 16
Stop! 17
20 Beaufort Wind chart

Note
The influence of the wind onto the surrounding is described clearly in the Beaufort Wind chart
below to provide an orientation for the crane operator!
The determining factor for all crane work in the actual wind speed at the job site of the crane!
The current wind speed can be checked at the nearest weather bureau!
Note the following: The wind speed on the boom may be higher than it is near the ground!
2.04 LIEBHERR 95
Wind force Wind speed Effect of the wind

Beaufort Description [m/s] [km/h] in the inland
0 Calm 0 to 0.2 1 No wind, smoke rises straight up
1 Slight air (draft) 0.3 to 1.5 1 to 5 Wind direction is shown only by observing
the trail of smoke, not by the wind sock
2 Light breeze 1.6 to 3.3 6 to 11 Wind can be felt on the face, the leaves
rustle, wind sock moves slightly
3 Gentle breeze 3.4 to 5.4 12 to 19 Leaves and thin twigs move, wind extends
a small breeze flag
4 Moderate breeze 5.5 to 7.9 20 to 28 Swirls up dust and loose paper, moves
twigs and thin branches
5 Fresh breeze 8.0 to 10.7 29 to 38 Small deciduous trees begin to sway, foam
forms at sea
6 Strong breeze 10.8 to 13.8 39 to 49 Thicker branches move; telephone lines
begin to whistle, umbrellas are difficult to
use
7 Stiff wind 13.9 to 17.1 50 to 61 Entire trees swaying; difficult to walk into
wind
8 Gale force wind 17.2 to 20.7 62 to 74 Breaks twigs off trees, walking becomes
difficult
9 Gale 20.8 to 24.4 75 to 88 Minor damage to property (chimney tops
and roofing tile are blown off)
10 Severe gale 24.5 to 28.4 89 to 102 Trees are uprooted, significant damage to
property
11 Violent storm 28.5 to 32.6 103 to 117 Extensive, widespread storm damage
12 Hurricane 32,7 and more 118 and more Major destruction
21 Consideration of wind conditions

It is imperative that the data regarding the permissible wind speeds is observed:
– For erection and take down of various boom configurations, see wind speed chart.
– For crane operation, see load chart.
– For the configured crane at “Crane not in service”, see wind speed chart.
96 LIEBHERR 2.04
21.1 Wind influences during erection and take down

WARNING
If a boom or a boom system is erected or taken down and the expected wind speeds are larger than
the maximum permissible wind speeds according to the wind chart, then the crane can topple over
and fatally injure personnel!
If wind speeds are expected which are larger than the maximum permissible wind speeds for
erection, then erection of the boom or the boom system is prohibited!
If wind speeds are expected, which are larger than the maximum permissible wind speeds for take
down, then the boom or the boom system must be taken down immediately!
21.2 Wind influences in crane operation

WARNING
It is prohibited to erect the crane to measure the wind speed!
Depending on crane application, for example:

1.) Lifting of large surfaced loads
2.) Working with long boom combinations
3.) Erection and take down of boom combinations
The crane operator must check with appropriate information sources about the expected wind speeds,
at:
1.) The start of crane operation
2.) Interruption of crane operation
3.) Taking up crane operation again
WARNING
If the crane is operated at wind speeds which are larger than the maximum permissible wind speeds
according to the load chart, then the can topple over and kill personnel!
If wind speeds are expected which are larger than the maximum permissible wind speeds for the
equipped crane, then the attachments and the boom must be taken down!
If wind speeds are expected which are larger than the maximum permissible winds speeds for the
crane operation, then it is prohibited to lift a load!
21.3 Wind influences when the “crane is not in service”

WARNING
If the crane is taken out of service in configured condition and the expected wind speeds are larger
than the maximum permissible wind speeds according to the wind chart, then the crane can topple
over and fatally injure personnel!
If wind speeds are expected which are larger than the maximum permissible wind speeds for
“taking the crane out of service”, then the attachments and the boom must be taken down!
Always take the boom down for safety reasons if weather conditions are unclear, see Erection and
take down charts!
2.04 LIEBHERR 97
22 Interruption of crane operation

22.1 Interruption of crane operation
If the crane operator must leave an equipped crane, then it must be ensured that there is no danger
for the crane or its surrounding area in case of an unforeseen event.
WARNING
Risk of fatal injury!
Situations may occur which could cause the crane to become unsafe if left unsupervised.
This could cause the crane to topple over, resulting in major personal injury and property damage.
Always keep the crane under full control!
Incidents which could occur (for example):

– The ground giving way due to severe rain
– Melting ice under the supports
– Bad weather, storms, thunderstorms
– Landslides
– Wash outs
– On mobile cranes:
Support cylinder failure
– On cranes with telescopic boom:
Luffing cylinder failure
– Vandalism
– there is no load on the hook
– The crane poses no traffic obstacle.
Note
If crane work must be interrupted if the crane is equipped, then it must be ensured that measures
are initiated in time by trained, qualified personnel, to bring the crane into a safe condition in case
something happens.
DANGER
Risk of accident!
If it is not possible to maintain full control over a rigged crane, the machinery and boom must be
taken down.
23 Taking up crane operation again

23.1 Taking up crane operation again
When resuming crane operation, the crane operator is required to check the condition of the crane
and the safety devices.
WARNING
Risk of accident!
If the crane operator leaves the cab, even for a short time, the operating mode setting must be
checked and reset, if necessary, before resuming crane operation.
Check operating mode settings and reset, if necessary.
98 LIEBHERR 2.04
24 Ending crane operation

24.1 Ending crane operation
Before the crane operator may leave the crane, the following prerequisites must be met:
Place the load fully on the ground and unhook from the crane hook.
On cranes with telescopic boom:
Telescope the telescopic boom all the way in and place the boom down.
On cranes with lattice mast boom:
Put down lattice mast boom and disassemble if necessary.
Bring the control lever (master switch) to 0-position.
Apply the parking brake on the crane chassis.
Turn the engine off and pull the ignition key.
On mobile cranes:
Secure the mobile crane to prevent unauthorized use. Make sure that the crane operator's cab
and driver's cab are not occupied. Lock the crane operator's cab and driver's cab.
On mobile cranes:
Secure the crane against uncontrolled rolling. See paragraph “Parking the vehicle”.
25 Turning / driving in reverse

WARNING
Danger of accidents when turning or driving in reverse!
When turning or driving in reverse, personnel can be overlooked or killed!
Objects can be severely damaged!
When turning or driving in reverse, the driver must act in such a way that he does not endanger
other traffic participants!
The driver may drive only in reverse or move back when it is ensured that persons or equipment
are not endangered! If this cannot be ensured, then he must use a guide.
An acoustical back up warning device will never replace the guide!
Make sure that there are no persons or objects behind the vehicle when driving in reverse!
Make sure that no personnel is injured or killed!
Make sure that no objects are damaged!
Driving in reverse is only permissible at slow driving speed (maneuvering speed)!
Adhere to the national regulations!
26 Parking the vehicle

Note
The “parking the vehicle” section is only to be observed for mobile cranes!
2.04 LIEBHERR 99
WARNING
Danger of accidents if the vehicle rolls off!
If the following points are disregarded by the crane driver, then personnel can be fatally injured.
It is prohibited to park the vehicle at a slope or an incline of more than 18%.
The parking brake must always be applied when parking the vehicle.
The ground on which the vehicle is parked must be level and have adequate load-bearing
capacity.

– The vehicle is standing on level ground with sufficient load bearing capacity.
– The parking brake is applied.
WARNING
The vehicle can roll off uncontrollably!
Under the following conditions, the vehicle must be secured against rolling away by using the
specified number of wheel chocks or wedges - in addition to the parking brake:
The vehicle is parked on a slope or an incline!
The vehicle is defective, particularly if the brake system is defective!
If all the specified wheel chocks are not placed directly behind the corresponding wheel, the
vehicle may roll off uncontrollably and personnel can be fatally injured.
All specified wheel chocks must be placed in such a way that they act against the downdrift force!
Place all specified wheel chocks tightly directly under the wheel!
Place all specified wheel chocks tightly so that they have an immediate braking action and keep
the vehicle in parking position!
100 LIEBHERR 2.04

2.05 Signs on the crane 028244-01
blank page!
2.05 LIEBHERR 101

028244-01 2.05 Signs on the crane
B110510
102 LIEBHERR 2.05

1 Warning signs
Note
Warning signs are safety signs which warn of a risk or danger.
For that reason, all warning signs on the crane must be complete and always legible.
Replace damaged warning signs immediately.
1.1 Warning note for unpinning the auxiliary boom on the pulley head
(position 5)
DANGER
If the auxiliary boom is not locked correctly to the pivot section, it can fall down.
Unpinning the auxiliary boom on the pulley head is prohibited!
1.2 Warning notes to unlock the auxiliary boom (position 6)
DANGER
If the auxiliary boom is not locked correctly to the pulley head, it can fall down.
Unpinning the auxiliary boom on the pivot section is prohibited!
2.05 LIEBHERR 103

1.3 Warning of suspended load (position 11)
DANGER
Risk of fatal injury under suspended load!
Standing under suspended loads is prohibited!
Keep away from the working range of the machine!
1.4 Warning of crushing danger (position 14)
DANGER
It is prohibited for anyone to remain in areas, where there is a crushing danger!
Keep away from the working range of the machine!
1.5 Danger of burns (position 29)
WARNING
Danger of burns!
Do not touch hot surfaces!
1.6 Warning of rotating parts (position 31)
104 LIEBHERR 2.05

WARNING
Rotating parts!
Rotating parts can cause finger and hand injuries.
Place no body parts into the danger zone!
1.7 Warning of crushing danger for hands (position 32)
WARNING
Crushing danger for hands!
Hands can be caught or crushed.
Keep hands away!
1.8 Warning of high voltage (position 40)
Note
Only for certain countries!
1.9 Slewing range (position 41)
2.05 LIEBHERR 105

Note
106 LIEBHERR 2.05

blank page!
2.05 LIEBHERR 107

B110511
108 LIEBHERR 2.05

2 Command and prohibition signs
2.1 Command sign

Note
Command signs are safety signs, which dictate a certain behavior.
For that reason, all command signs on the crane must be complete and always legible.
Replace damaged command signs immediately.
2.1.1 Limitation of maximum driving speed (position 21)
Note
2.1.2 Limitation of maximum driving speed (position 42)
Note
2.1.3 Use personal protective equipment (position 63)
DANGER
Risk of falling!
Use the personal protective equipment!
2.05 LIEBHERR 109

2.2 Prohibition signs

Note
Prohibition signs are safety signs, which prohibit a behavior, which could result in danger.
For that reason, all prohibition signs on the crane must be complete and always legible.
Replace damaged prohibition signs immediately.
2.2.1 Access for unauthorized personnel prohibited (position 12)
DANGER
If the crane is accessed by unauthorized personnel, life threatening injuries can occur!
Access is strictly prohibited during crane operation!
2.2.2 Access to the area is prohibited (position 64)
WARNING
Risk of injury!
If the prohibited area is accessed, injuries can occur.
Do not access the area!
2.2.3 Access prohibited (position 66)
WARNING
Risk of falling!
If the crane is accessed by unauthorized personnel, life threatening injuries can occur.
Do not climb on the crane!
110 LIEBHERR 2.05

blank page!
2.05 LIEBHERR 111

B110512
112 LIEBHERR 2.05

3 Notice signs
Note
Notice signs are signs which provide additional information in text and symbol form.
For that reason, all notice signs on the crane must be complete and always legible.
Replace damaged notice signs immediately.
3.1 Warning marks “left” (position 3)
3.2 Warning marks “right” (position 4)
3.3 Chassis operating instructions (position 16)

Note
Read and observe the operating instructions before operating the crane!
3.4 Notice sign for vehicle height (position 19)
Note
Vehicle height 4.0 m (13.1 ft)
2.05 LIEBHERR 113

3.5 Operating instructions for maneuvering mode (position 22)

Note
Read and observe the operating instructions before operating the crane!
3.6 Warning of fatal electric shock (position 33)
DANGER
If the boom or the hoist rope is under electric current, then death or severe injuries can occur if
anyone touches the crane, the vehicle or the load!
Keep away from the crane and the load!
3.7 Read the operating instructions (position 35)
CAUTION
Read and observe the operating instructions!
Avoid unsafe operation and dangerous maintenance practices!
The crane may only be operated if the contents of the operating instructions have been read and
understood!
If the operating instructions are lost, request a new manual from your nearest dealer!
3.8 Notice sign for refueling (position 49)
114 LIEBHERR 2.05

CAUTION
Damage to the engine!
If the crane is refuelled with fuel not specified in the operating instructions, then engine damage can
occur.
Observe the operating instructions!
3.9 Note for speed limiter (position 50)

Note
Read and observe the operating instructions before operation!
3.10 Notice sign for data logger
3.11 Warranted maximum sound power level (position 77)
3.12 Warning marks “left” (position 98)
2.05 LIEBHERR 115

Note
3.13 Warning marks “right” (position 99)
Note
116 LIEBHERR 2.05

2.06 Antifall guards on the crane 026691-01
blank page!
2.06 LIEBHERR 117

026691-01 2.06 Antifall guards on the crane
B199896
118 LIEBHERR 2.06

1 Antifall guards on the crane
DANGER
Danger of falling!
During assembly and disassembly, personnel must be secured with appropriate antifall guards to
prevent them from falling. If this is not observed, personnel could fall and suffer life-threatening
injuries.
All assembly work from a height of 2 m must generally be carried out using suitable aids (lifting
platforms, scaffolding, ladders, auxiliary crane, etc.)! The height above which
assembly/disassembly work must be carried out with aids depends on national regulations. The
national regulations must be adhered to!
If work cannot be carried out on the ground or using such aids, then assembly personnel must be
secured with suitable personal protective equipment (such as safety belts) to protect against
falling!
Any antifall guards (railings) fitted to the crane superstructure must be brought and secured into
their correct position prior to assembly/dismantling.
Note
The signs 1 mark the fastening points, where assembly personnel must engage the approved
safety belts to secure itself against falling.
2 Fastening points
2.1 Fastening points on the telescopic boom
Fastening points A, fastening point B, fastening point C, fastening point D and fastening point E are
installed on the telescopic boom.
DANGER
When working aloft, there is a danger of falling!
If the following notes are not observed, the assembly personnel could fall and suffer life-threatening
injuries!
Before any assembly / disassembly work and maintenance work on the crane superstructure and
the telescopic boom, the assembly personnel must attach the approved safety belts and protective
devices.
For assembly / disassembly work, the ladder with hook device is engaged on pipe 2, see also
section “Installing hook device on ladder”.
The assembly personnel must secure itself with approved safety belts on fastening point A, or
fastening point B, or fastening point C, or fastening point D or fastening point E to prevent falling.
DANGER
Danger of damage!
Never hang loads or objects on fastening points A, fastening point B, fastening point C, fastening
point D or fastening point E.
2.06 LIEBHERR 119

B102241
120 LIEBHERR 2.06

3 Attachment points on folding jib
Note
For assembly / disassembly work on the folding jib and the folding jib extension, the supplied
ladder 11 with hook device 12 must be used.
The ladder 11 is carried along under the driver's cab.
DANGER
Danger of accidents due to incorrect hook device!
The two hooks 14 on the hook device 12 may not point downward to the roadway during transport!
The hook device 12 must be installed on the ladder 11 in such a way that, during transport, the two
hooks 14 are pointed “upward” to the driver’s cab!
After assembly / disassembly work, install and secure the ladder 11 with hook device 12 properly
under the driver's cab.
Before starting to travel, check if the hooks 14 of the hook device 12 are pointing upward to the
driver’s cab.
3.1 Using the ladder

DANGER
Risk of accident!
If the following notes are not observed, the ladder can tip and the assembly personnel can fall from
the ladder and sustain life-threatening injuries!
Damaged ladders may not be used!
Use only the supplied ladder with cross brace 9!
The hook device 10 on the ladder serves as protection from falling over. For all assembly /
disassembly work on the folding jib, folding jib extension and telescopic boom, the ladder with
hook device 10 must be used!
The ladder must be set up stable and safely accessible.
For safe handling of ladder, observe the safety notes on the ladder!
3.2 Installing the hook device on the ladder

Before using the ladder, the hook device 12 must be installed on a rung.
Push the ladder with the required rung against the locking plates 13 on the hook device 12 (
point X), see illustration 1, illustration 2.
Result:
– the locking plates 13 spring in direction of the arrow and release the receptacle on the hook
device 12 for the rung, see illustration 3
push the hook device 12 “upward”

Result:
– the locking plates 13 spring (arrow) “back” into their original position by themselves and secure the
rung, see illustration 4
2.06 LIEBHERR 121

B102242
122 LIEBHERR 2.06

3.3 Attachment points on folding jib / folding jib extension

DANGER
If the following notes are not observed, the ladder can tip and the assembly personnel can fall from
the ladder and sustain life-threatening injuries!
For all assembly / disassembly work on the folding jib and the folding jib extension, use the
ladder 11 with cross brace 10 and hook device 12, see section “Installing the hook device on the
ladder”.
Hang the ladder with hook device 12 on the corresponding attachment point and set it up stable.
Do not hang the ladder. The ladder must be resting on the ground.
For safe handling of the ladder, observe the safety notes on the ladder.
Step on the ladder only with “clean shoes”.
For assembly / disassembly work on the folding jib and the folding jib extension, note the following
attachment points for the ladder:
– Attachment point D
– Attachment point E
– Attachment point F
– Attachment point G
– Attachment point H
– Attachment point I
2.06 LIEBHERR 123

B199897
124 LIEBHERR 2.06

4 Railings on the crane superstructure
CAUTION
Risk of crushed limbs!
When moving the railing, limbs can be crushed!
Be especially careful when moving the railing!
4.1 Moving the railing into position for assembly / disassembly

Release the tension element 4.
Pull the latch 9 and move the railing 1 in position of assembly / disassembly.
Secure the railing 1 in position for assembly / disassembly: Lock the clamping lever 5.
Release the lock 8.
Move the bar 7 in position for assembly / disassembly until the lock 8 engages again.
Release the tension element 4.
Swivel the railing 3 in position for assembly / disassembly.
Secure the railing 3 in position for assembly / disassembly: Lock the clamping lever 5.
Release the lock 8.
Move the bar 6 in position for assembly / disassembly until the lock 8 engages again.
4.2 Moving the railing into transport position

Release the lock 8.
Move the bar 6 in transport position until the lock 8 engages again.
Swivel the railing 3 into their transport position.
Secure the railing 3 with the tension element 4.
Release the lock 8.
Move the bar 7 in transport position until the lock 8 engages again.
Release clamping lever 5.
Move the railing 1 into transport position and lock the latch 9.
2.06 LIEBHERR 125

B199944
126 LIEBHERR 2.06

5 Cranes with luffing* cab
Note
On cranes with luffing* or telescoping* cab, the fastening points are installed on the rear on the
crane superstructure.
5.1 Fastening points on the crane superstructure

The fastening point J is installed on the crane superstructure.
DANGER
If the following notes are not observed, the assembly personnel could fall and suffer life-threatening
injuries!
Before any assembly / disassembly work and maintenance work on the crane superstructure, the
assembly personnel must wear the approved safety belts and protective devices.
For assembly / disassembly and maintenance work on the rear of the crane superstructure, hang
ladder 5 in plate 6.
Use only the supplied ladder with cross brace 9.
For safe handling of ladder, observe the safety notes on the ladder.
Step on the ladder only with “clean shoes”.
The assembly personnel must secure itself with approved safety belts on fastening point J to
prevent falling.
DANGER
Risk of damage!
Never hang loads or objects on the fastening point J.
Wear the approved safety belt and protective devices.

Clean dirty shoes.
Hang ladder 5 in plate 6 and set it up securely.
Hang the safety belt on fastening point J.
2.06 LIEBHERR 127

027456-00 2.10 General safety technical notes for driving with dolly
B104580 Example of travel operation with dolly
128 LIEBHERR 2.10

2.10 General safety technical notes for driving with dolly 027456-00
1 Travel operation with dolly
WARNING
An accident risk exists in the event of non-compliance with the operating instructions for the dolly!
Separate dolly operating instructions have been issued for each dolly and crane model.
Non-observance of the dolly operating instructions, the following description or the operating
instructions provided by the dolly manufacturer could result in fatal injury or cause serious damage to
the crane!
Read and comply with the separate dolly operating instructions, the following description and the
operating instructions provided by the dolly manufacturer!
Note
General points!
Driving the crane with a dolly is only permitted when making transit journeys on solid roads with
large turning radii and when road conditions are good!
Drive with utmost caution and at an appropriate speed!
It is prohibited to drive a crane with dolly on off-road terrain or building sites!
The drive must check the route beforehand!
The telescopic boom is secured to prevent it from accidentally telescoping out!
If the hook block should remain reeved in, secure it in such a way so that no persons, objects or
similar can be injured or damaged by swinging movements!
It is only permitted to use the "normal road driving" program during dolly operation. Other driving
programs are prohibited!
The complete crane with attached dolly should be checked by the customer and taken on an
extensive test run to verify its suitability for operation!
Dolly operation is only permitted when the hydraulics are switched on and fully functional!
The crane with dolly should only be driven by authorized and trained expert personnel!
The crane operator bears sole responsibility when driving a crane with attached dolly!
Any national regulations specific to individual countries must be observed!
Abbreviation Item
A Height of vehicle
B Travel of the dolly tower when cornering
1.1 Coupling and decoupling the dolly to/from the crane

The following is to be observed when coupling and decoupling the dolly to/from the crane:
– The crane must always be driven to the dolly. Never allow the dolly to run into the crane.
– No persons may stand in the space between the crane and dolly when reversing the crane. The
guide must be positioned so that he is able to observe the traffic situation and the coupling
process. He must be able to see the driver.
– Only when the mechanical connection between the crane and dolly has been made, may the
supply lines be connected and the parking brake released.
– When the dolly is to be decoupled from the crane, the parking brake is first to be engaged and the
dolly secured against rolling before the mechanical connection between crane and dolly is
released.
2.10 LIEBHERR 129

130 LIEBHERR 2.10

1.2 Height of vehicle
Abbreviation Item
A Height of vehicle
α Inclination angle of crane chassis
x Height difference when turning the support
y Turning distance of support
It is imperative to comply with the following instructions:

– The vehicle height for level roads is given in the separate operating instructions for the dolly. The
driver must take into account any deviations when travelling over level crossings, ramps, craters
or other changes affecting road conditions.
– The crane driver must check the vehicle height before starting to travel. Adjusting the dolly height
will also change the vehicle height. Take into account the existing vehicle height.
– The chassis on some crane models can be slightly tilted to increase the boom clearance (approx.
0.5°). If the boom is placed on the chassis support on such crane models, the vehicle height may
increase above 4 m. Take into consideration the existing vehicle height specified in the dolly
– Hydraulic accumulator cylinder and temperature changes:
If the dolly is equipped with a hydraulic accumulator cylinder, take into account that the gas
volume increases with temperature. This can alter the vehicle height. Check the vehicle height
before starting to travel and at regular intervals when driving. Also check the vehicle height if the
ambient temperature changes by 10 °C.
– Hydraulic accumulator cylinder or support rests on rotating bearings in dolly:
The hydraulic accumulator cylinder or support turn to the rear around their horizontal axis when
cornering or manoeuvering. This can increase the vehicle height. Take this into account when
considering the overhead clearance. After the vertical position is reached, it is possible for the
hydraulic accumulator cylinder or support to turn further to the rear. This results in an angle
between the vertical and the cylinder/support leaning to the rear. Do not exceed the angle given in
the separate operating instructions for the dolly. If no angle is specified on the drawing, do not
exceed an angle of 15°. The crane operator must verify and ensure there is no risk of collision with
boom or dolly components within this angular range. Stop driving when this angle is reached.
Refer to the separate operating instructions for the dolly.
NOTICE
Risk of collision!
Check the overhead clearance of underpasses, bridges and other structures before attempting to
drive under them. Ensure the overhead clearance is greater than the current vehicle height and
that there is sufficient clearance between the crane and the obstacle.
2.10 LIEBHERR 131

132 LIEBHERR 2.10

1.3 Driving on inclines and slopes
Abbreviation Item
ß Inclination angle (slope of roadway)
L Length of horizontal roadway section
Rc Maximum permitted roadway bend radius
Note
The luffing cylinder is fully retracted!
The road conditions over which the crane can travel are limited by the clearance of the boom from the
ground. The permissible values are given in the separate operating instructions for the dolly! Level
crossings, ascents/descents, ramps, as well as entries and exits on inclines with a slope angle
ß higher than that specified in the separate dolly operating instructions, should only be traversed in
exceptional circumstances. See section entitled “permitted exceptional circumstances” for more
information.
WARNING
Risk of accident if bending radius is less than the maximum permissible value of Rc!
Do not drive on a roadway with a bending radius Rc lower than that specified in the separate dolly
operating instructions. If this is not observed, severe errors may occur:
The crane can be severely limited in its steering ability!
The dolly can lose contact with the ground and swing uncontrollably to the side!
The rear tires or axles of the crane can be overloaded!
The luffing cylinder can be damaged!
Personnel can be killed or injured!
Do not fall below the maximum permissible bending radius of Rc!
1.3.1 Permitted exceptional circumstances when driving on slopes and inclines

The permitted inclination angle ß for entering and exiting slopes and inclines can exceed the value
given in the separate dolly operating instructions by maximum 1.5° when operating the crane at
walking speed (maximum 5 km/h) and providing the danger area is blocked off. Block off the danger
area to avoid any risk of injury or damage to objects when the dolly loses contact with the ground
causing the dolly and boom to swing out to the side. The opposite lane should be blocked off and the
crane secured to prevent collisions. No persons other than the driver should be present inside the
danger area. The driver must wear a seat belt. Position an adequate number of helpers outside the
danger area for supervision purposes. The helpers should signal the driver to stop the traversing
movement if it becomes apparent that the dolly is losing contact with the ground or the crane tires are
becoming increasingly deformed. In this case the traversing movement should be immediately halted.
2.10 LIEBHERR 133

134 LIEBHERR 2.10

1.4 Cornering and shunting

Approach bends with utmost caution and at an appropriate speed. The boom and crane
superstructure can swing out sharply when cornering or manoeuvering. Do not exceed the turning
radius given in the separate operating instructions for the dolly. If any part of the boom protrudes into
the opposite lane, block off the lane to avoid accidents. If any part of the boom protrudes over the
hard shoulder, take appropriate safety measures to prevent injury or material damage. Stop driving if
this is not possible. Refer to the separate operating instructions for the dolly.
WARNING
High accident risk!
The centre of gravity for the superstructure is displaced outwards when cornering or manoeuvering.
This can cause the drive wheels to spin!
The dolly and telescopic boom could tip over if the speed is excessive!
The telescopic boom swings out!
Risk of fatal injury to personnel or crane damage!
Carefully drive around bends at a suitable speed!
No persons may stand in the space between the crane and dolly when cornering and shunting!
The following is to be observed when cornering and shunting:

– The distance between the rear of the chassis and the dolly changes when cornering and shunting.
• The dolly may only be steered out of the direction of travel insofar as:
• The supply lines cannot be damaged
• the crane and the dolly cannot collide
• the maximum permissible turning radius is not exceeded
– Test drives are to be carried out in order to determine the radius of operation limits and in order to
gain experience.
– If the danger area cannot be fully judged by the driver when shunting or reversing, then a guide is
required.
– The guide must be positioned so that he is able to observe the traffic situation and the reversing
area of the crane.
He must be able to see the driver.
– Dolly with towing bar:
If the dolly is hauled by the carriage engine by means of a towing bar, then a relative movement
occurs when cornering or shunting in the longitudinal direction between the suspension mounting
on the boom and the dolly. Usually a support, cylinder or rail mounted car is used on the dolly in
order to compensate for this movement. It is to be ensured, that these parts cannot collide with the
dolly or the payload on the dolly. If one observes the dolly from above, there is an
angle W between the boom longitudinal axis and the dolly longitudinal axis when cornering or
shunting. This leads to a transverse loading of the dolly. The dolly is to be observed and the
cornering manoeuvre or shunting manoeuvre is to be aborted before damage can occur or the
dolly threatens to topple.
2.10 LIEBHERR 135

136 LIEBHERR 2.10

1.5 Dolly
The dolly is usually not supplied by Liebherrwerk Ehingen.
Abbreviation Item
C Axle distance
D Self-steering axle
The dolly should be designed as follows:

– With a parking brake.
– The dolly brake must be designed to brake the full weight of the dolly and the load of the
telescopic boom plus any other loads. The dolly wheels should not lock even when maximum
braking is applied. The dolly braking system must comply with the relevant statutory regulations
for a given application.
– The connection points on the dolly are to be designed to match the connection points on the
boom.
– The dolly is to be dimensioned so that it can withstand all operationally-relevant loads.
– The supply lines for the electrical, pneumatic and, where applicable, hydraulic supplies between
the crane and the dolly do not form part of the scope of delivery from Liebherr-Werk Ehingen.
The supply lines are to be designed in such a way as that all operational movements can be
carried out without damage. The connections fitted by Liebherr-Werk Ehingen are generally to be
found on the rear of the chassis. It should be considered that the distance between the rear of the
vehicle and dolly can extend considerably during cornering or shunting.
– The dolly should be equipped with pneumatic suspension. A leaf suspension is sufficient for
hydraulic accumulator cylinders with a soft spring characteristic.
– Spring characteristic:
On some crane models, the spring travel that the dolly suspension must absorb is specified in the
separate dolly operating instructions. The spring characteristic for the dolly suspension must be
designed to permit 70% of the axle loads, as specified in the separate operating instructions for
the dolly, for the given spring travel.
– Dolly without towing bar:
The boom of the crane is used as towing bar for this dolly type. The roadway levels of crane and
dolly can be twisted against each other. In order to compensate for this, the dolly is to be designed
with an articulated joint 1. The joint must allow for angular motion of at least +/-15° in order to
enable an axis in the dolly longitudinal direction.
An internal centering is to be provided on the connection of the telescopic boom 2 and dolly 3 The
distance a on the outer side is to be selected slightly larger than the distance b on the inner side
for this purpose.
– Long dolly without towing bar:
The last dolly axle or axle group must be self-steering when the dolly is pulled through the boom
and the axle distance C between the first and last dolly axle is larger than 3 m. It is not permitted
to lock the self-steering axle or axle group. Such dollys are typically used in California or Florida.
Refer to the separate operating instructions for the dolly.
– Dolly with towing bar:
If the dolly is to be hauled by means of the chassis with a towing bar, then a fully-pivoting rotatable
connection around all 3 axles is to be planned for between the dolly chassis and the boom. In
addition, relative movement occurs when cornering or shunting in the dolly's longitudinal direction
between the mounting point on the boom and the dolly. This movement is to be taken into
consideration in the design of the dolly.
– The applicable work safety and accident prevention guidelines in the area of operation must be
observed.
2.10 LIEBHERR 137

138 LIEBHERR
3.00 Crane chassis operation
LIEBHERR 139
027093-00 3.01 Operating and monitoring instruments on the crane chassis
B194457
140 LIEBHERR 3.01

3.01 Operating and monitoring instruments on the crane chassis 027093-00
1 Vehicle operating and control instruments
1.1 General operating instruments

1 Service brake
2 Engine control
3 Parking brake
4 Tachograph • Speedometer
• Odometer
• Clock
5 Steering wheel
6 Left-hand steering • Switch from low beam to high beam
column switch • Operate headlamp flasher
• Turn signal activation (left / right)
• Activate windshield wiper (0, intermittent, I, II)
• Activate windshield wiper system
• Activate signal horn
7 Right-hand steering • Retarder:
column switch Switch position 0 - 1
Switch position 2 -5* (with eddy current brake*)
• Tempomat
• Temposet
• Manual throttle
• Shift 1 gear up or down with manual transmission
8 Foot switch • Pneumatic steering wheel angle and height adjustment
10 Driver's seat • Note:
For description “Adjusting driver's seat” see Chapter 3.02
Before setting off.
14 Battery box
15 Battery master switch
3.01 LIEBHERR 141

B103438
142 LIEBHERR 3.01

17 Display unit
18 Keyboard • The function control on the button lights up: function has
been selected and performed
• The function control on the button flashes: function has
been selected but not performed
• Acoustic signal (beep) sounds when button is
pressed: function that is not permitted has been selected
19 Center console
20 Switch, button • Switch: switch between right / left outside mirror
• Button: electric mirror adjustment
26 Switch * • Battery charger, superstructure / chassis shift
27 Switch * • Dolly mode
28 Switch * • Camera - washing pump
31 Ignition starter switch • Position: P/0/I/II
32 Operating hours counter
33 Built-in socket 24 V
34 Rotary switch • Switchover chassis operation / superstructure operation
35 Cigarette lighter
36 Axle pressure indicator • Axles 1 and 2, left side
37 Axle pressure indicator • Axles 1 and 2, right side
38 Axle pressure indicator • Axles 4 and 5, left side
With axle pressure compensation: Axles 3 to 5, left side
39 Axle pressure indicator • Axles 4 and 5, right side
With axle pressure compensation: Axles 3 to 5, right side
40 Switch * • Auxiliary heating / engine preheating
41 Ashtray
42 Tank • Windshield washer fluid
43 Interior illumination
44 Outlet nozzles • For heating / ventilation / air conditioning system*
45 Switch • Left power window
46 Switch • Right power window
47 Switch • Right power window
48 Tachograph
49 Switch • Switch off intarder
Note:
The switch 49 is under the center console.
50 Switch • Switch transfer gearbox to freewheel
Note:
The switch 50 is under the center console.
60 EMERGENCY OFF
switch*
3.01 LIEBHERR 143

B103439
144 LIEBHERR 3.01

1.2 Operating elements on camera-monitor*

61 Button • ON / OFF
62 Remote control sensor
63 Brightness sensor • Automatic brightness regulation
64 Camera selection button
65 Menu button • The following functions can be selected in the menu:
• Scale
• KA 1 (mirror)
• Automatic time
• Color
• Brightness
• Contrast
• Tint (only for NTSC)
66 Button • Increase volume
67 Button • Decrease volume
68 Switch • Day / night switch
69 Button • Shift channel up
70 Button • Shift channel down
3.01 LIEBHERR 145

B199845
146 LIEBHERR 3.01

1.3 Keyboard
100 Drive range switch • Reverse “R”
101 Drive range switch • Neutral “N”
102 Drive range switch • Drive “D”
104 Button • Shift, automatic / manual shift mode
Function control does not light up: automatic shift mode
Function control lights up: manual shift mode
105 Button • Shift up 1 gear in manual shift mode
107 Button • Switchover creeper gear / road gear
Function control lights up: creeper gear is activated
Function control does not light up: road gear is activated
Function control flashing: error
Function control flashing rapidly: transfer gearbox switched
to freewheel, button 50 pressed
108 Button • Shift down 1 gear in manual shift mode
109 Display • Function code
110 Button • Information button (diagnostics) system error in LICCON Error
Code (LEC) on display unit
112 2-handed button • Vehicle level, raise left front
113 2-handed button • Vehicle level, raise right front
114 Display • Heating level, brightness level
115 Button • Display and keyboard brightness adjustment
116 Button • Diagnostics
117 Button • Independent rear axle steering, steering effort to right
118 Button • Independent rear axle steering, steering effort to left
119 2-handed button • Vehicle level, lower left front
120 2-handed button • Vehicle level, lower right front
121 2-handed button • Switch on “Road driving” steering program
122 2-handed button • Switch on “All-wheel steering” steering program
123 2-handed button • Switch on “Crab steering” steering program
124 2-handed button • Switch on “Reduced swing-out rate” steering program
125 2-handed button • Switch on “Independent steering” steering program
127 2-handed button • Vehicle level, raise left rear
128 2-handed button • Vehicle level, raise right rear
129 2-handed button • Automatic level control, road driving
130 2-handed button • Locking the axle suspension
135 2-handed button • Vehicle level, lower left rear
136 2-handed button • Vehicle level, lower right rear
3.01 LIEBHERR 147

B199845
148 LIEBHERR 3.01

138 2-handed button • Add longitudinal differential lock in transfer gearbox + add axle
1 ( with 10x8 drive*)
140 2-handed button • Add transversal differential lock axle 1 ( with 10x8 drive*) + axle
2
141 2-handed button • Add longitudinal differential lock axle 4 + add transversal
differential lock axle 4 + axle 5
142 2-handed button • Axle pressure compensation, axles 1+ 2 / 3 - 5
143 2-handed button • Confirmation for 2-handed operation
Note:
The “2-handed button” must be operated for:
Vehicle level regulation
Enabling steering programs
Enabling differential locks
Locking the axle suspension
Axle pressure compensation, axles 1+ 2 / 3 - 5
144 Button* • Switch auxiliary heating on/off
145 Button • Driver's cab heating warmer
146 Button • Driver's cab heating cooler
147 Button • Fan speed (blower), faster
148 Button • Fan speed (blower), slower
149 Button* • Heated seat, driver's side
150 Button • Driving light
151 Button* • Fog lamps
152 Button* • Air conditioning system
153 Button • Recirculated air
154 Button • Fresh air
155 Button • Footwell air supply
156 Button • Front window air supply
157 Button* • Heated seat, passenger's side
158 Button • Parking lights
159 Button • Rear fog light
160 Button* • Outside mirror heater
164 Button • Sliding beam illumination, manual on/off
165 Button • Rotating beacons
166 Button • Hazard warning system
3.01 LIEBHERR 149

B198094
150 LIEBHERR 3.01

1.4 Display unit

180 Control light* • Auxiliary heater
flashes: in case of fault
181 Control light • Steering
illuminates: steering operational
flashes quickly: fault in steering system, with fault code
indicator
flashes slowly: LSB bus link problem
182 Warning light • Engine cooling water level too low
183 Control light • Air filter soiled
184 Control light • Diesel engine preglow system
185 Warning light • Steering circuit I (steering pump)
186 Warning light • Steering circuit II (auxiliary steering pump)
187 Warning light • Speed limiter
188 Control light • Clutch released, control light illuminates during:
• startup procedure, service brake + “Drive range switch
forwards D” operated
• Shifting procedure
189 Warning light • Transmission defects
192 Control light* • Release with Dolly mode*
flashes: When driving with Dolly* and switch 27 on, the
hydraulic oil pressure for clearing the slewing gear
brake/lowering brake of the luffing cylinder drops below a
permitted limit.
193 Control light* • Automatic braking force reduction
195 Control light • High beam
196 Control light • Low beam
197 Control light • Rear fog light
198 Control light* • Rotating beacon
199 Control light* • Rotating beacon
200 Control light • Engine brake active
201 Control light • Parking brake closed
202 Control light* • Eddy current brake active
204 Warning light • Brake pad worn
207 Control light* • ABS at trailer
ABS Antilock Brake System
illuminates: ABS error
flashes: communication error between ABS vehicle electronics
At a driving speed in trailer mode greater than approx. 10 km/h,
this warning light must go off.
208 Control light • CAN bus error
210 Display • Vehicle direction of travel left / right
211 Display* • Trailer direction of travel left / right
212 Warning light • Hazard warning system
213 Control light • Rotating beacon
214 Control light • Rotating beacon
3.01 LIEBHERR 151

B198095
152 LIEBHERR 3.01

220 Control light • Tempomat or Temposet active

221 Display • Engine speed [rpm]
222 Display • Transmission in neutral “N”
223 Display • Gear indicator
Note:
Brief display of Tempomat and Temposet speed settings.
224 Warning light • flashes: active system fault or service indication
Pressing the “i-key” 110 causes the system fault or service
indication to appear on the display 225.
• illuminates: active operating error
Operating error appears automatically on display 225.
225 Display • LICCON Error Code (LEC) with pressed-in “i-key”
226 Bar chart • Gear oil temperature [deg], 30 °C - 120 °C
227 Warning light • Gear oil temperature too high, greater than 110 °C
228 Bar chart • Fuel reserve [%], 0 to 100%
229 Warning light • Fuel reserve less than 10 %
230 Bar chart • Engine coolant temperature [deg], 30 °C - 120 °C
231 Warning light • Engine coolant temperature or charge air temperature too high
or engine fault
232 Bar chart • Engine oil pressure [bar], 0 bar - 10 bar
233 Warning light • Oil pressure too low / oil temperature too high
234 Bar chart • Battery voltage [V], 21 V - 30 V
235 Warning light • Charge monitoring
236 Bar chart • Compressed air supply I [bar], 0 bar - 10 bar
237 Warning light • Compressed air supply I less than 5.5 bar
238 Bar chart • Compressed air supply II [bar], 0 bar - 10 bar
239 Warning light • Compressed air supply II less than 5.5 bar
240 Bar chart • Compressed air supply III [bar], 0 bar - 10 bar
241 Warning light • Compressed air supply III less than 5.5 bar
242 Bar chart • Current brake pressure with operated brake circuit I [bar],
0 bar - 10 bar
243 Warning light • flashes: brake pressure sensor in circuit I defective
244 Bar chart • Current brake pressure with operated brake circuit II [bar],
0 bar - 10 bar
245 Warning light • flashes: brake pressure sensor in circuit II defective
3.01 LIEBHERR 153

B198096
154 LIEBHERR 3.01

1.5 Support control unit

Left support control unit:
250 Button • Retract right front support cylinder
251 Button • Extend right front support cylinder
252 Button • Retract right rear support cylinder
253 Button • Extend right rear support cylinder
254 Button • Extend left front sliding beam
255 Button • Retract left front sliding beam
256 Button • Extend left rear sliding beam
257 Button • Retract left rear sliding beam
258 Button • Retract left front support cylinder
259 Button • Extend left front support cylinder
260 Button • Retract left rear support cylinder
261 Button • Extend left rear support cylinder
262 Display • Right front support force display
263 Display • Right rear support force display
264 Display • Left front support force display
265 Display • Left rear support force display
266 Display • Slope indicator
267 LED 1°
268 LED 5°
269 Button • Support control unit release
Note:
Before the support cylinders or the sliding beams can be
moved, the support control unit release 269 must first be
operated.
271 Button • Retract all support cylinders and align horizontally
272 Button • Extend all support cylinders and align horizontally
273 Button • Engine off
274 Button • Engine on
275 Button • Reduce engine Rpm
276 Button • Increase engine Rpm
277 LED • Illuminates with support control unit release
3.01 LIEBHERR 155

B198096
156 LIEBHERR 3.01

Right support control unit:

266 Display • Slope indicator
267 LED 1°
268 LED 5°
269 Button • Support control unit release
Note:
Before the support cylinders or the sliding beams can be
moved, the support control unit release 269 must first be
operated.
271 Button • Retract all support cylinders and align horizontally
272 Button • Extend all support cylinders and align horizontally
273 Button • Engine off
274 Button • Engine on
275 Button • Reduce engine Rpm
276 Button • Increase engine Rpm
277 LED • Illuminates with support control unit release
280 Button • Retract right front support cylinder
281 Button • Extend right front support cylinder
282 Button • Retract right rear support cylinder
283 Button • Extend right rear support cylinder
284 Button • Extend right front sliding beam
285 Button • Retract right front sliding beam
286 Button • Extend right rear sliding beam
287 Button • Retract right rear sliding beam
288 Button • Retract left front support cylinder
289 Button • Extend left front support cylinder
290 Button • Retract left rear support cylinder
291 Button • Extend left rear support cylinder
292 Display • Right front support force display
293 Display • Right rear support force display
294 Display • Left front support force display
295 Display • Left rear support force display
3.01 LIEBHERR 157

B198097
158 LIEBHERR 3.01

1.6 Earthing the mobile crane

300 Pin • Connection to earth
Note:
In order that the mobile crane can be earthed, the pin 300 for
the connection to earth is installed. Mobile crane earthing, see
chapter 2.04.
3.01 LIEBHERR 159

026693-01 3.02 Turntable assembly
B198140
160 LIEBHERR 3.02

3.02 Turntable assembly 026693-01
1 General checks before starting to drive

Various checks must be performed before starting to drive.
For a detailed description of the tasks listed below, refer to chapter 7.04.
1.1 Checking the oil level and filters

Check the oil level in the vehicle engine.
Check the oil level in the automatic transmission and transfer gear box.
Check the oil level in the hydraulic reservoir for steering, support and axle suspension.
Check the filter on the hydraulic oil tank.
1.2 Checking the fuel level

Note
Bleed the fuel system.
If the fuel tank has been run dry, then the fuel system must be bled.
Do not run the fuel tank dry.
Check the available amount of fuel on the fuel gauge in the driver's cab.
1.3 Checking the coolant level

WARNING
Danger of injury due to scalding of the skin!
Check the coolant level only when the engine is cold.
Fill the coolant expansion tank until it overflows on the filler neck.
1.4 Checking the tires

While doing this, also check the spare tire*.
Note
See Crane operating instructions, chapter 8.01.
3.02 LIEBHERR 161

B199846
162 LIEBHERR 3.02

1.5 Checking the general transport condition

Note
Transport on public highways:
For transport on public highways the driving conditions of the crane as described in chapter 3.04
must be adhered to to retain the maximum axle load of 12 t.
DANGER
Risk of accident due to improper transport condition!
Locking mechanisms, cotter pins and retaining pins must be installed and attached in such a way,
that they cannot loosen up by themselves during travel and cause damage.
The safety measures, locking measures and checks described in paragraph “General transport
condition” must be performed!
To be in a suitable condition for transport, all loose parts on the mobile crane must be fastened and
secured.
While driving, the wind speed sensor may not be installed on the telescopic boom.
Point crane superstructure in direction of travel and mechanically lock to prevent twisting.
The telescopic boom must be fully telescoped in and placed down on the boom receptacle.
Secure the telescopic boom to prevent it from extending by itself.
Retract and secure the step next to the crane cab.
Close the windows and doors 4 of the crane operator's cab.
Secure the assembly ladder under the front bumper.
Individually secure the four sliding beams of the hydraulic supports with pins 1/1a to prevent them
from extending unintentionally. Secure the four pins 2 in the respective transportation retainers.
Move the four support plates to the transport position and secure them with pins 5 to prevent them
from extending unintentionally.
Take the four chocks and secure them in their holders.
Lock the switch boxes 6 for the left and right support control units.
Secure all locks on tool boxes, cabinet doors and covering.
Check that all locking pins used only for crane operation are present and secure them for
transport.
Set the rotary switch 3 to “Travel mode”.
Place the steering program “On-road travel”.
Set the axle suspension / axle locking system to level for “suspended” on-road travel, see chapter
3.03.
Attach the hoist rope on the front tow coupling 7 and tighten.
3.02 LIEBHERR 163

B199847
164 LIEBHERR 3.02

1.6 Checking the lights

Make sure that the battery master switch and the ignition are turned on.
DANGER
Risk of accident if lighting is defective!
Have any defective lights repaired by an expert before setting off.
Crane lighting:
– Low beam 1
– High beam 2
– Front and rear parking lights 3
– Fog lights* 4
– Turn signals 5
– Tail lights 6
– Brake lights 7
– Back up light 8
– Rotating beacons 9
– Corner marker lights 10
– Rear fog light 11
– License plate lamp 12
– Side marking lights 13
– Course holding light 14
Check all lights before starting to travel.
3.02 LIEBHERR 165

B191514
166 LIEBHERR 3.02

2 Work station - Driver's cab
DANGER
Risk of accident from incorrect mirror and/or steering wheel positions!
Move driver's seat, mirrors and steering wheel to required positions before setting off.
Never adjust the driver's seat, the mirror or the steering wheel while driving.
2.1 Adjusting the driver's seat

The pneumatically suspended driver's seat 10 can be adjusted to suit every body size.
If desired, the driver's seat can be equipped with IPS* (Integrated Pneumatic System). IPS* provides
additional side lumbar support.
The suspension rigidity is adjusted automatically.
Block the horizontal suspension 1.
Infinitely variable height adjustment with “Memory function” 7.
Adjust the horizontal setting 2.
Adjust the backrest 8.
Adjust the seat cushion incline 6.
Adjust the seat cushion depth 4.
Lower the oscillation system 5.
Adjust the cushioning 9 (infinitely variable).
Adjust the seat heater* 3.
Backrest, adjust the lower section (LWS*) 10.
Backrest, adjust the upper section ( LWS*) 11.
Adjust the side cushion guide (IPS*) 12.
3.02 LIEBHERR 167

B195972
168 LIEBHERR 3.02

2.2 Adjusting the mirrors

Clean outside mirrors before starting to drive and adjust to suit the driver's field of view.
Actuate the switch 20 on the center console 19.
Result:
– You can switch between the left and right outside mirrors.
– Mirror is adjusted.
2.3 Adjusting the steering wheel

The steering wheel is adjusted pneumatically.
Press the button 8.
Result:
– The angle and height of the steering wheel are adjusted.
2.4 Turning the heater / ventilation on

The driver's cab can be heated or ventilated to the desired temperature.
For detailed description, see chapter 6.01.
To adjust the heating or ventilation, use the keypad 18.
2.5 Fastening the seat belt

DANGER
Risk of fatal injury if seat belt is not worn!
If the seat belt is not worn during travel operation, the driver or the passenger can be fatally injured in
case of an accident or total braking action.
Before driving the crane and while driving, all occupants must wear the seatbelt.
Put on seat belt.
3.02 LIEBHERR 169

B198139
170 LIEBHERR 3.02

2.6 Checking the important operating instruments

DANGER
Risk of fatal injury due to defective main controls!
Have any defective functions repaired by an expert before setting off.
Make sure that the battery master switch 15 is turned on. Otherwise the controls cannot be checked.
For some checks, the ignition must also be turned on.
2.6.1 Checks with the ignition turned off

Hazard warning system: Press button 166 with function control and check.
Rotating beacons: Press button 165 with function control and check.
Parking lights: Press button 158 with function control and check.
2.6.2 Checks with the ignition turned on

Headlight: Press the button 150 with function control, check indicator light 195 and indicator
light 196.
Fog lamps* (only with driving light or parking light switched on): Press button 151 with function
control and check.
Rear fog lamps* (only with driving light or parking light switched on): Press button 159 with
function control and check indicator light 197.
Heater: To increase temperature, press button 145 with function control and check.
Heater: To reduce temperature, press button 146 with function control and check.
Auxiliary heater*: Press button 144 with function control and check indicator light 180.
Fan: Press button 147 and button 148 with function control and check.
Windshield wiper / washer system: Check the steering column switch 6 with reservoir for
windshield washer system.
Check the horn 6.
Turn signals: Operate steering column switch 6 with indicator light 210 and check.
3.02 LIEBHERR 171

026694-00 3.03 Axle suspension system
B199851
172 LIEBHERR 3.03

3.03 Axle suspension system 026694-00
1 General
1.1 Description
All axles are guided by longitudinal and cross control arms. The axles are hydro-pneumatically sprung
via maintenance-free hydraulic cylinders, the height can be adjusted and they can be hydraulically
locked. Depending on the driving condition the axles can be interconnected via axle pressure
compensation.
1.2 Axles sprung
1.2.1 Driving condition 1

See illustration 1 for more information.
Used for driving on roads. All axles are sprung. Spring travel +150 mm/-150 mm. In order to improve
fording capability the entire chassis can be raised by 150 mm. In order to reduce height to clear low
obstacles the entire chassis can be lowered by 150 mm. On a slope the entire chassis can be tilted +/-
9.3° to the side. The side stability of the vehicle when cornering is safeguarded by the hydraulic axle
suspension.
1.3 Axles locked

For supporting the crane. All axles are locked.
Axle pressure compensation occurs between axle pairs 1 + 2 and 4 + 5.

Used for “driving with equipment in place” on level ground. All axles are locked.
Axle pressure compensation occurs between axles 1 + 2 and 3 - 5.
3.03 LIEBHERR 173

B199852
174 LIEBHERR 3.03

2 Axle suspension system
DANGER
Risk of injury when operating axle suspension/axle locking system!
Ensure that no persons are present in the crane danger zone!
2.1 Road driving / off-road driving

For transit journeys on roads, motorways and for off-road driving, switch button 130 off.
Result:
– The function control on button 130 does not light up.
– All axles are sprung in this position.
– The level of the crane can be controlled.
2.2 Level control

Level control can be manual or automatic.
Ensure that the following preconditions are met:
– the vehicle is on a level surface
– the engine is running
– the axle suspension is sprung
– the transmission is in neutral “N”
CAUTION
Danger of damage!
Do not perform level control unless the vehicle is stationary!
Perform level control on a level and load-bearing surface.
Never raise or lower the vehicle fully when driving on an uneven road surface.
The function control on button 129 must be on during the level control procedure.
– If the function control does not light up, stop the procedure immediately!
– Arrange to have fault remedied by an expert.
When the level control procedure is complete the function control on button 129 must go off. If the
function control does not go off, have fault remedied by an expert.
2.2.1 Automatic level control

Button 143 and button 129 operate the automatic level control. The crane is automatically moved to a
level position (driving height for road driving) by the level switches attached to the suspension
cylinders.
Press button 143 and button 129 simultaneously until the function control on the
button 129 flashes.
Result:
– The function control on the button 129 lights up during automatic level control and flashes when
the end position is reached.
– The function controls for manual level control (buttons 112, 113, 119, 120, 127, 128, 135 and 136)
flash when the corresponding suspension cylinders have reached the level position for road
driving.
3.03 LIEBHERR 175

B199852
176 LIEBHERR 3.03

2.2.2 Manual level control

The level position is adjusted manually by pressing the 2-handed button 143 for manual level control.
The suspension cylinders are filled or emptied.
WARNING
Danger!
Performing manual level control on public highways is only permitted in order to adapt the crane to
special situations such as lowering the crane to reduce the height in order to drive under a bridge.
Level control must only be performed in special situations and with the vehicle stationary!
Raising vehicle
Press and hold down button 143 and then press button 112.
Result:
– The left front vehicle level is raised.
Result:
– The right front vehicle level is raised.
Result:
– The left rear vehicle level is raised.
Result:
– The right rear vehicle level is raised.
Raising entire vehicle

Press and hold down button 143 and then press button 112, button 113, button 127, button 128.
Result:
– The vehicle level is fully raised.
3.03 LIEBHERR 177

B199852
178 LIEBHERR 3.03

Lowering vehicle
Result:
– The left front vehicle level is lowered.
Result:
– The right front vehicle level is lowered.
Result:
– The left rear vehicle level is lowered.
Result:
– The right rear vehicle level is lowered.
Lowering entire vehicle

Press and hold down button 143 and then press button 119, button 120, button 135, button 136.
Result:
– The vehicle level is fully lowered.
3.03 LIEBHERR 179

B199852
180 LIEBHERR 3.03

3 Axle locking system
3.1 General
All axles are to be locked in the following circumstances:
1.) Supporting the crane
2.) Driving with the equipment in place
3.2 Switching on axle locking

Ensure that the surface on which the vehicle is parked is level and has adequate load-bearing
capacity.
Press button 130 and button 143.
Result:
– The function control on button 130 lights up.
– The hydro-pneumatic suspension on all axles is locked.
3.3 Supporting the crane

A detailed description of how to support the crane can be found in chapter 3.05.
3.4 Driving with the equipment in place

For a detailed description, refer to the separately issued manual “Driving with the equipment in place”,
chapter 15.01.
3.03 LIEBHERR 181

026695-02 3.04 Travel operation
B199853
182 LIEBHERR 3.04

3.04 Travel operation 026695-02
1 Crane driving conditions

Before the crane can be driven on public roads, the telescopic boom must be fully telescoped in and
placed on the receptacle frame.
Note
Driving on public highways.
Observe national regulations at all times!
1.1 Axle loads up to 12 t

– the telescopic boom is fully telescoped in and placed down,
– the hoist rope is hung and tightened on the front tow coupling,
– the axle suspension system has been set to “suspended”,
– the vehicle is at the level setting for on-road driving.
Axle
1+2 3-5
With: 1 driver
10 x 8 drive
Without: Folding jib
Hook block / load hook
Winch 2
Counterweight: No counterweight
Axle loads: Total: 60.0 t 2 x 12.0 3 x 12.0
1.2 Axle loads more than 12 t

DANGER
Increased danger of accidents!
The brake stopping distance is greater due to the greater overall weight!
The wear on brake linings is increased and there is an increased danger of overheating the brakes.
The steering system, service brake, parking brake and retarder no longer meet the regulations!
The service life of all components affected by the increased axle load such as: Brakes, tires, wheel
rims, axles and all drive, suspension and steering components is reduced.
Check the affected parts more frequently!
3.04 LIEBHERR 183

B199853
184 LIEBHERR 3.04

1.3 Drive with a total weight of 75 t

Note
Observe the relevant applicable national traffic regulations!
NOTICE
Danger of clutch damage!
The clutch will overheat or be damaged if the following points are not observed!
In manual shift mode and on level roads, drive off the crane “in gear 2 or lower”.
On inclines greater than 6 %, only drive the crane away when the off-road gear in the transfer gear
box has been engaged and “only drive in gear 2”.
The vehicle should only be manoeuvred or positioned when the off-road gear is engaged.
Do not attempt to drive off if the vehicle rolls back and a forward gear has been selected.
3.04 LIEBHERR 185

B198104
186 LIEBHERR 3.04

2 Starting and stopping the engine

Do not put a full load on the engine until it is at operating temperature.
2.1 Starting the engine

– the battery master switch 15 is turned on,
– the parking brake 3 is applied,
– the transmission is in neutral position “N”,
– the rotary switch 34 is set to chassis operation.
2.1.1 If the coolant temperature is above 20 °C or the engine is at operating

temperature
Turn the ignition starter switch 31 to position “I”.
Result:
– The indicator light 184 blinks.
– The charge indicator light 235 lights up.
– The engine is ready to start.
Turn the ignition starter switch 31 to position “II” and start the engine.
Troubleshooting
The engine does not start after a maximum of 10 seconds?
Wait for 1 minute. The starter can be operated three times for 10 seconds per attempt with a one
minute break in between.
3.04 LIEBHERR 187

B198104
188 LIEBHERR 3.04

2.1.2 With flame starting device at coolant temperature of less than 20 °C

To improve the cold start process and the warm-up phase, the engine is equipped with a flame
starting device. The flame starting device switches on automatically at coolant temperatures
below 20 °C.
The flame starting device turns off automatically if:
– the engine is not started when it is ready,
– the engine is started while the control light 184 is illuminated,
– the coolant temperature reaches 20 °C while the engine is running.
Note
Functionality of the battery in the cold season.
The starting capacity of the battery is considerably reduced in cold temperatures: For example, at
a temperature of -10 °C, it has only 66 % of its normal capacity.
Once the engine has been turned off, store batteries in a heated room, if possible.
Turn the ignition starter switch 31 to position “I”.

Result:
– The indicator light 184 lights up first and then starts to blink after a short time.
– The charge indicator light 235 lights up.
– The engine is ready to start.
Turn the ignition starter switch 31 to position “II” and start the engine.
Troubleshooting
Is the indicator light 184 blinking quickly?
The flame-start control unit has identified a defect.
Remedy the problem.
3.04 LIEBHERR 189

B198104
190 LIEBHERR 3.04

2.2 Checking the instruments after starting the engine

The following indicator lights must turn off when the engine is running:
Check the indicator light for the engine oil pressure 233.
Troubleshooting
Does the engine oil pressure control light 233 stay illuminated or is no oil pressure displayed?
There is a danger of engine damage.
Turn the engine off immediately!
Check the indicator light - preheat 184.

Check the charge indicator light 235.
Check the indicator light - gear oil temperature 227.
Check the indicator light - steering circuit I 185.
The steering circuit II control light 186 only extinguishes at a speed of approx. 10 km/h.
Check the indicator light - steering circuit II 186.
Check the indicator light - air pressure circuit I 237.
Check the indicator light - air pressure circuit II 239.
Check the indicator light - air pressure circuit III 241.
3.04 LIEBHERR 191

B199854
192 LIEBHERR 3.04

2.3 Turning the engine off
2.3.1 Parking
See also paragraph entitled “Stopping the vehicle (Parking)”.
– the parking brake 3 is applied,
– the transmission is in neutral position “N”.
– the rotary switch 34 is set to chassis operation.
CAUTION
Risk of damaging the engine!
Turn off the engine immediately in case of dropping or significantly fluctuating oil pressure,
reduced power and RPM without a throttle control change, heavy exhaust, increasing coolant
temperature or suddenly occurring abnormal engine noises!
Turn the ignition starter switch 31 back to the stop.

Pull the ignition starter switch 31 off and store it.
2.3.2 Turning off the engine in case of danger

In case of danger, the engine can be turned off immediately by pressing the EMERGENCY OFF
switch* 60.
CAUTION
Operating the EMERGENCY OFF switch* 60.
Only use the EMERGENCY OFF switch* 60 in the event of a clear emergency. Use of the
EMERGENCY OFF switch* 60 for normal operation is not permitted!
Press the EMERGENCY OFF switch* 60.

Result:
– The engine will be turned off immediately.
To turn off the EMERGENCY OFF switch* 60 once it has been activated:
Unlock with the ignition key.
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3 Driving
3.1 Changing the low idle speed

The idle speed increase will be automatically reduced after preselecting the drive range switch “D” or
“R”.
3.1.1 Changing the low idle speed with the steering column switch
If required, the idle speed can be changed when the vehicle is not operational and the transmission is
in neutral position “N” using the steering column switch 7.
After the engine is started, the low idle speed will be automatically regulated, depending on the
coolant temperature.
Hold the steering column switch 7 in position 8.
Result:
– The idle speed increases cyclically by approx. 50 rpm.
Tap the steering column switch 7 in position 8.

Result:
– The idle speed increases by approx. 50 rpm.
Release the steering column switch 7.

Result:
– The engine runs at the attained RPM.

Result:
– The idle speed reduces cyclically by approx. 50 rpm.

Result:
– The idle speed reduces by approx. 50 rpm.
Release the steering column switch 7.

Result:
– The engine runs at the attained RPM.

Result:
– The low idle speed increase is turned off.
3.1.2 Changing the low idle speed with the engine regulation
Set the idling speed with the engine regulation 2.
Press button 7.
Result:
– The engine runs at the adjusted RPM.
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3.2 Parking brake
3.2.1 Applying
DANGER
Vehicle can roll off uncontrollably!
If the manual lever 3 is not correctly engaged when the parking brake is applied, then the vehicle can
roll off uncontrollably and fatally injure personnel.
It is imperative to ensure that the hand lever 3 is correctly locked into place. The hand lever 3 may
not be permitted to be pushed forward (without being pulled out first).
Pull the hand lever 3 back until it locks into place.

Result:
– The parking brake is locked on.
– The indicator light 201 lights up.
3.2.2 Releasing
Ensure that the compressed air supply III for the required brake release pressure is available.
DANGER
Vehicle can roll off uncontrollably!
When the parking brake is released, the crane can start to move immediately and fatally injure
personnel.
When releasing the parking brake, brake the crane with the service brake or accelerate using the
engine regulation!
Pull back the hand lever 3 hand lever to the stop in the lever's longitudinal direction and push
forward.
Result:
– Parking brake is released.
– The indicator light 201 turns off.
Troubleshooting
The parking brake does not release, even though the manual lever 3 has been pushed forward?
The compressed air supply III for the required brake release pressure is not available. The warning
light 241 lights up.
Pull the hand lever 3 back again.
Fill compressed air supply III until the warning light 241 extinguishes.
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3.3 Service brake

DANGER
Danger of fatal injury due to defective service brake!
Carry out a test braking procedure immediately after starting to drive.
Depress the pedal 1 and check the service brake.

Result:
– The displays on bar graph 242 and on bar graph 244 must move proportionally to the pedal path
of the service brake.
3.4 Retarder
The retarder consists of the engine brake, the hydraulic intarder and the eddy current brake*.
3.4.1 Operating conditions

The retarder can only be operated with the engine turned on. If the retarder is being actuated, it is not
possible to accelerate.
Sensible use of the retarder by anticipating driving modes reduces wear on the service brake and
thereby reduces operating costs.
DANGER
Utmost care should be taken when operating the retarder!
Switch through the individual stages one by one while constantly observing the vehicle handling
characteristics.
On long downhill slopes

On long downhill slops, select a shift that leaves further shift stages available for additional braking
procedures, which may be required.
If the braking effect is not sufficient, slow down the vehicle with the service brake and shift down.
On snow, ice and dirty road surfaces
DANGER
In the event that the wheels lock when operating the retarder, select a lower shift stage!
Careful use of the retarder will ensure safe and sure deceleration even under bad road surface
conditions.
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3.4.2 Actuation
The retarder is operated using the 6-stage steering column switch 7. Five switch settings are
available.
Change through the steering column switch 7 stage by stage and not jerkily in order to avoid any
overbraking.
Actuate the steering column switch 7.
Result:
– In switch position 1, the intarder is active.
– In switch settings 2 to 5 the intarder, the engine brake and the eddy current brake* are active.
If the road surface is wet:

Engage briefly in each shift position to avoid locking the wheels.
WARNING
Danger of overheating!
As soon as the vehicle is at a standstill or no more deceleration is required, turn the retarder off.
The steering column switch 7 may be reset with one pull without pauses between the stages.
Reset the steering column switch 7 to stage 0.
Result:
– The retarder is turned off.
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3.5 Automatic gear box
3.5.1 General
The automatic gear box can be used in automatic or in manual shift mode. The transmission has 12
forward gears and 2 reverse gears. The current gear positions will be indicated on the display 223.
3.5.2 Switching between automatic and manual shift mode

When the ignition is turned on, the automatic mode is activated automatically. In the neutral “N” and
reverse “R” drive range, the manual mode is always activated.
Press button 104 to change between automatic and manual shift mode.
Result:
– The indicator light on button 104 does not light up: Automatic mode
– The indicator light on button 104 lights up: Manual shift mode.
3.5.3 Setting off
DANGER
Danger of fatal injury due to rolling crane!
When the parking brake 3 is released, the vehicle starts to roll immediately.
When the parking brake 3 is released, brake crane with service brake 1 or accelerate with engine
control 2.
The starting gear is automatically established by the transmission according to the preceding drive
resistance. It can be manually corrected upward or downward. To do so, change to manual shift
mode. Thereafter it is possible to change immediately back to automatic mode.
In starting mode, the clutch is open if engine control is not activated. The clutch will close if the engine
control is lightly activated.
– the crane is at a standstill,
– the parking brake 3 has been applied.
Apply the service brake 1 gently.
Press the button 100 for reverse driving.
or
Press the button 102 to drive forward.
Correct the starting gear, if necessary.
Release the service brake 1.
Activate the engine regulation 2 gently.
Result:
– The clutch engages. This is indicated by a slight jerk.
Release parking brake 3 and activate engine regulation 2 as required.

Result:
– The vehicle begins to roll.
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3.5.4 Uphill or downhill driving

If the engine control 2 is brought back to the 0 setting due to the traffic situation on ascending and
descending gradients, the transmission initially switches back to the starting gear. Shortly before the
vehicle comes to a stop in this gear, the clutch is released and the tractive power or brake force is
interrupted. This can result in the vehicle suddenly rolling back or accelerating. Operating the engine
regulation 2 again will not immediately provide tractive power, since the clutch must be closed first.
On an ascending gradient:
Apply the service brake 1 after opening the clutch.
On a descending gradient, expect a reduction in braking effort when opening the clutch:
Apply the service brake 1 more firmly.
3.5.5 Driving downhill, followed shortly by an ascending gradient

In the event of driving downhill, followed shortly by an ascending gradient, the automatic gear box
does not immediately recognize that the vehicle is located on an ascending gradient.
Press the button 104.
Result:
– Manual shift mode will cut in.
Shift down using the steering column switch 7.

or
Shift down using button 108.
Select the gear according to the gradient.
Result:
– Automatic mode will cut in.
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3.5.6 Selecting the driving direction

Make sure that the vehicle is at a standstill.
Reverse driving direction “R”
This setting is used to move the vehicle backwards.
Result:
– The indicator light on button 100 lights up.
Neutral position “N”

This setting is used to start the engine and for low idle operation.
Use the neutral position also if the vehicle is not occupied and the engine is running.
DANGER
In the event that the driver is required to leave the crane while the engine is running, ensure that
the parking brake is locked on correctly and that the wheels are chocked.

Result:
Driving direction forward “D”

This driving range is selected for general driving in a forward direction.
Result:
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3.5.7 Automatic mode

In automatic mode, the driver operates only the engine control or the brake. Gear shifts are carried out
automatically by the system depending on drive condition and usage. Depending on the preset driving
direction, the transmission automatically selects a starting gear. It can be manually adjusted to the
driving conditions.
Apply the service brake before switching from neutral “N” to a drive range. If this is not done, an
acoustic warning signal sounds and an operating instruction appears on the display unit 225.
The display 223 contains the following information:

– Automatic mode: A
– Not assigned: B
– Gear engaged: C
– Gear engaged: D
3.5.8 Manual shift mode

In manual shift mode the gears are selected by the driver using the steering column switch 7 or the
key 105 and the key 108.
Apply the service brake before switching from neutral “N” to a drive range. If this is not done, an
acoustic warning signal sounds and an operating instruction appears on the display unit 225.
In manual shift mode, it is not possible to drive with the tempomat or temposet.
If an attempt is made to shift up in the 12th forward gear or an attempt is made to shift down in the 1st
forward gear or the 1st reverse gear, an acoustic signal is heard and an operating instruction appears
on the display unit 225.
In the event that an attempt is made to shift down further than the gear permitted by the transmission,
an acoustic signal will sound and a notice will appear on the display unit 225.

– Gear selected: A
– Gear selected: B
– Gear engaged: C
– Gear engaged: D
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Selecting the gear with the steering column switch

The steering column switch can be used to shift through one or more gears simultaneously. The
steering column switch returns to the initial setting after each operation.
Shifting up
Push the hand lever 7 briefly upwards.
Result:
– Shift up by one gear.
Push the manual lever 7 up and hold.

Result:
– The gears are shifted up cyclically in 1/2 second intervals.
Shifting down
Push the manual lever 7 briefly downward.
Result:
– Shift down by one gear.
Push the manual lever 7 downward and hold.

Result:
– The gears are shifted down cyclically in 1/2 second intervals.
Selecting the gear with the button

With button 105 and button 108, can be one or more gears shifted up or down simultaneously.
Shifting up
Press the button 105 briefly.
Result:
– Shift up by one gear.
Press and hold button 105.

Result:
– The gears are shifted up cyclically in 1/2 second intervals.
Shifting down
Press the button 108 briefly.
Result:
– Shift down by one gear.
Press and hold button 108.

Result:
– The gears are shifted down cyclically in 1/2 second intervals.
3.5.9 Warning display

Transmission error
The transmission carries out a self-check as soon as the ignition is turned on. If there is
a transmission error, the error message “CH” will appear on the display 223 either immediately or
soon after the ignition has been turned on.
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– Transmission error: A
– Transmission error: B
– Gear engaged: C
– Gear engaged: D
Turn the engine off and remedy the transmission error.
Loss of air pressure
In the event of loss of air pressure, the transmission may no longer be able to shift.
This is shown via the display 223 “AL”.
The engine will stall if the clutch does not open due to insufficient air pressure when stopping.

– Loss of air pressure: A
– Loss of air pressure: B
– Gear engaged: C
– Gear engaged: D
Start to drive only if there is sufficient air pressure.
Clutch overloaded
The clutch could overheat in the event that too high a demand is placed on it.
This is shown via the display 223 “CL”.

– Clutch overheating: A
– Clutch overheating: B
– Gear engaged: C
– Gear engaged: D
DANGER
If the driver ignores the error message “CL”, the clutch closes of its own accord when the accelerator
pedal is operated. This can result in the engine stalling and the crane rolling back.
Stop the vehicle immediately and allow the clutch to cool off!
212 LIEBHERR 3.04

CAUTION
Danger of clutch damage!
If the ignition is turned off and then turned immediately back on while the error message “CL” is
showing, the error message “CL” will no longer be displayed even though the clutch is overheated.
It is imperative to let the clutch cool down!
Stop the vehicle and allow the clutch to cool off until it is possible to shift gears again.
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3.6 Creeper gear (off-road gear / manoeuvring mode)

Creeper gear consists of the following operating modes:
1.) Off-road gear
Off-road gear can be added separately.
2.) Manoeuvring mode.
Manoeuvring mode assumes off-road gear.
3.6.1 Off-road gear

When switching over to off-road driving, there is an automatic switch-over to manual shift mode,
starting in 2nd gear. Switching (V1...V4 or R1 ...R2) is only possible when the vehicle is stationary.
Addition of off-road gear

Result:
– Off-road gear is added.
– The function control on the button 107 lights up.
Apply the service brake 1 gently and hold down.

or
Release the parking brake 3.
Result:
– The vehicle begins to move.
Turning off off-road gear

Result:
– Off-road gear is turned off.
– The function control on the button 107 turns off.
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3.6.2 Manoeuvring mode

Manoeuvring mode is only designed for the following driving situations:
– Slow moving (manoeuvring) in narrow spaces.
– Slowly backing in and out of a parking space.
– For driving with the equipment in place, see chapter 15.01.
CAUTION
Damage to transmission!
If manoeuvring mode is added when the vehicle is stuck, the transmission can be damaged.
Manoeuvring mode with a stuck crane vehicle is prohibited!
Select manoeuvring mode only when absolutely necessary.

– the off road gear is added,
General
The way that the engine and transmission work together in manoeuvring mode is substantially
different to normal operation.
In normal mode engine control 2 gives only maximum engine torque. The electronic (torque control)
handles the closing and opening of the clutch as well as gear changes.
In manoeuvring mode, the closing of the clutch depends directly on the position of the gas pedal. At
a light touch of the engine regulation 2, the clutch connects and transmits a small amount of torque,
which is however not sufficient to move the vehicle. Further activation of the engine control 2 closes
the clutch ever more forcefully until with full activation the clutch is 100 % closed. Engine RPM
remains close to constant at idling speed up to an accelerator pedal position of 50 %. Only after that
does engine RPM increase to a maximum of 1400 rpm. The engine torque is adjusted to the demands
on it (engine speed regulation).
While the clutch is slipping, heat is generated and the clutch gets hot. If the clutch gets too hot, the
“warning clutch overloaded” “CL” is issued. See warning information display 223. The slipping of the
clutch is related to wear and tear, and the higher the clutch temperature, the greater the wear and
tear.
For that reason, the following situations must be avoided:
– Holding the vehicle on a hill using just the engine control.
– Lengthy manoeuvering at very low speed.
– Shaking the vehicle free when stuck.
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Activating manoeuvring mode

Apply the service brake 1 gently and hold down.
or
Using the steering column switch 7 engage gear 1.
or
Press button 108 to engage gear 1.
Result:
– The manoeuvring mode is added.

– Manoeuvring mode: A
– Gear selected: B
– Not assigned: C
– Gear engaged: D
Release the parking brake 3.

Result:
– The vehicle begins to move.
Turning off the manoeuvring mode

Using the steering column switch 7 change 1 gear up.
Using the button 105 change 1 gear up.
Result:
– The manoeuvring mode is turned off.
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3.7 Important indicator instruments while driving
3.7.1 Checking the steering circuit II

At a driving speed of approximately 10 km/h the warning light 186 for hydraulic steering circuit II goes
off.
Check the warning light 186.
Troubleshooting
Are warning light 185 and warning light 186 blinking?
A sensor error is present.
Remedy the cause of the problem.
Troubleshooting
Warning light 186 does not turn off?
Steering circuit II is not operative.
Immediately bring the crane to a standstill and remedy the cause of the problem.
3.7.2 Checking the engine oil pressure

Engine oil pressure display on bar chart 232 of 0 bar - 10 bar.
Check the warning light 233 and the bar graph 232.
Troubleshooting
Does the oil pressure drop while driving and not increase even when increasing RPM?
The engine is not lubricated if there is insufficient or no oil pressure. This causes engine damage.
Bring the crane to a standstill immediately and turn the engine off.
3.7.3 Checking compressed air supply I, II and III

The warning lights 237, 239, 241 do not light up.
Check the warning lights 237, 239, 241.
Troubleshooting
Are all or one of the warning lights 237, 239, 241 illuminated?
The brake system is not operational.
Immediately bring the crane to a standstill and remedy the cause of the problem.
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3.7.4 Checking the fuel reserve

Do not drive until the fuel tank is empty, otherwise the fuel system will have to be bled.
Fuel quantity displayed on bar graph 228 in percent (%), 0 to 100 %.
If the fuel reserve is below 10 % (approx. 34 l) the yellow indicator light 229 lights up.
Check the indicator light 229.
If the yellow indicator light 229 lights up:
Add fuel.
Troubleshooting
The indicator light 229 blinks.
Remedy the error.
3.7.5 Checking the coolant temperature

Display of coolant temperature on bar graph 230 from 30 °C - 120 °C.
Check the warning light 231 and the bar graph 230.
If the coolant temperature is too high while driving:
First try to reduce the temperature to the permitted range of between 85 °C - 90 °C by means of
load reduction and engine RPM increase.
Troubleshooting
Does the warning light 231 light up while driving?
Excessive coolant temperature causes excessive engine temperature. This causes engine damage.
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3.7.6 Checking the gear oil temperature

Display of gear oil temperature on bar graph 226 from 30 °C - 120 °C.
The temperature display on bar graph 226 must be within the approved range for normal driving
mode.
Check the warning light 227 and bar graph 226.
Troubleshooting
Does the warning light 227 blink?
Remedy the error.
Troubleshooting
Does the warning light 227 light up while driving?
Troubleshooting
Does the display on bar graph 226 reach the red zone?
Immediately bring the crane to a standstill.
Shift the transmission into neutral position “N”.
Allow engine to run at approx. 1500 rpm.
If the oil temperature does not drop into the approved temperature range within a short time:
Turn the engine off.
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3.8 Tempomat
A drive speed of more than 20 km/h can be stored using the tempomat. The tempomat is operated
with the steering column switch 7. When the tempomat is activated, the control light 220 illuminates
and the speed setting will be indicated for a brief period on the display 223.
Use the tempomat only when traffic conditions permit a steady speed. It may not be possible to
maintain the speed on ascending or descending gradients.
Take the foot off the gas pedal when the tempomat is turned on.
DANGER
Danger of skidding on slippery road surfaces!
Do not use tempomat on slippery road surfaces!

– the automatic mode is turned on,
– the driving speed is greater than 20 km/h,
– the service brake and the retarder are not activated.
3.8.1 Saving the tempomat speed

Ensure that tempomat is not activated.
Accelerate the vehicle to the desired speed.
Operate the steering column switch 7 in direction 8 or direction 9.
Result:
– The stored speed will be briefly indicated on the display 223.
3.8.2 Displaying the current tempomat speed

Ensure that tempomat is activated. The indicator light 220 lights up.
Operate the steering column switch 7 in direction 8 or direction 9.
Result:
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3.8.3 Changing the current tempomat speed

Operate the steering column switch 7 in direction 8 and again within 10 seconds in direction 8.
Result:
– The speed is increased by 2 km/h.

Result:
– The speed is continuously increased by 2 km/h.
Operate the steering column switch 7 in direction 9 and again within 10 seconds in direction 9.
Result:
– The speed is reduced by 2 km/h.

Result:
– The speed is continuously reduced by 2 km/h.
3.8.4 Turning off the tempomat

Accelerate engine control for more than 10 sec.
If the engine control is used to accelerate for less than 10 sec., the crane will brake back to the speed
stored in the tempomat when the engine control is released.
The stored speed is deleted when the ignition switch is turned back to position “0”.
Move the steering column switch 7 in direction 6.
Apply the service brake or retarder.
The speed drops below 10 km/h.
3.8.5 Reusing the old tempomat speed

If the tempomat has been turned off but the ignition starter switch has not been turned back to “0”, the
previous speed can be resumed.
Move the steering column switch 7 in direction 9.
Result:
– The speed will flash on the display 223.
Move the steering column switch 7 within 2 seconds again in direction 9.

Result:
– The displayed speed will be resumed.
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3.9 Temposet
The driving speed can be limited from a speed of 10 km/h and above using the temposet. The
temposet is operated with the steering column switch 7. When the temposet is activated, the indicator
light 220 lights up and the speed setting will be indicated for a brief period on the display 223.
– the automatic mode is turned on,
– the driving speed is greater than 10 km/h.
3.9.1 Saving the temposet speed

Ensure that temposet is not activated.
Accelerate the vehicle to the desired speed.
Press the button 7.
Result:
3.9.2 Displaying the current temposet speed

Ensure that temposet is activated. The indicator light 220 lights up.
Press the button 7.
Result:
3.9.3 Changing the current temposet speed

Press button 7 and hold steering column switch 7 in direction 8. Within 10 seconds, push it in
direction 8 again.
Result:
– The speed is increased by 2 km/h.
Press button 7 and hold steering column switch 7 in position 8.

Result:
– The speed is continuously increased by 2 km/h.
Press button 7 and hold steering column switch 7 in direction 9. Within 10 seconds, push it in
direction 9 again.
Result:
– The speed is reduced by 2 km/h.
Press button 7 and hold steering column switch 7 in position 9.

Result:
– The speed is continuously reduced by 2 km/h.
3.9.4 Turning off the temposet

The temposet speed is deleted at ignition starter switch position “0” and the vehicle-specific speed is
activated.
Push the steering column switch 7 for more than 3 seconds in direction 6.
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3.10 Ending driving
3.10.1 Stopping
Slow down the crane until it comes to a standstill.
The selected drive range can remain turned on.
For longer stops (more than 1 minute), use the button 101 to shift the gear box into neutral position
“N”. This will reduce clutch wear and increase the service life of the clutch.
Use the service or parking brake to ensure that the crane does not roll away.
3.10.2 Interrupting driving while the engine is running

Press the button 101 and shift the gear box into neutral “N”.
Close the parking brake 3.
Result:
3.10.3 Parking the vehicle when the engine is running

Press the button 101 and shift the gear box into neutral “N”.
Close the parking brake 3.
Result:
If the crane has been operated at full engine output or in the event that the coolant temperature is
above 95 °C:
Allow the engine to run without a load at low idle speed for 1-2 minutes.
If special functions (parking light, rotating beacons, hazard warning lights, auxiliary heating*) are
turned on:
Turn off special functions.
Turn off the ignition 31 and pull out the ignition key.
Turn off the battery master switch 15 and remove the trip cam.
Lock the operator's cab.
Secure the vehicle with chocks against uncontrolled rolling away.
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4 Differential locks
This vehicle is equipped with differential locks, which can be added for off road driving, on unpaved
roadways and in wintery conditions.
With the differential locks enabled a speed restriction of up to 40 km/h is active.
The differential locks may only be added when the vehicle is at a standstill and in the following
sequence:
1.) Longitudinal differential lock in transfer gearbox + addition of axle 1 (with 10x8 drive)*.
2.) Longitudinal differential lock axle 4 + transversal differential lock axle 4 + axle 5.
3.) Transversal differential lock axle 1 (with 10x8 drive)* + axle 2.
CAUTION
Danger of damage to drive axles!
Only add / turn off differential locks when the vehicle is stationary!
Never add differential locks when the driving wheels are turning!
Drive carefully, do not start jerkily, do not drive at full throttle!
Drive only straight away and not around corners!
Only drive on difficult terrain (e.g. sand, slush, loose or slippery subsoil etc.) with differential locks.
4.1 Addition of longitudinal differential lock in transfer gearbox + axle 1

(with 10x8 drive)*
– the vehicle is stationary,
Result:
– Longitudinal differential lock in transfer gearbox + axle 1 (with drive 10x8)* is added.
Troubleshooting
The function control on the button 138 blinks.
The gears of the differential are in tooth-on-tooth position.
Place the gear and start to drive carefully.
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4.2 Addition of longitudinal differential lock axle 4 + transversal

differential lock axle 4 + axle 5
– longitudinal differential lock in transfer gearbox + axle 1 (with drive 10x8) is added.
Result:
– Longitudinal differential lock axle 4 + transversal differential lock axle 4 + axle 5 is added.
Troubleshooting
4.3 Addition of transversal differential lock axle 1 (with 10x8 drive)* +

axle 2
– longitudinal differential lock in transfer gearbox + axle 1 (with drive 10x8) is added.
Result:
– Transversal differential lock axle 1 (with drive 10x8)* + axle 2 is added.
Troubleshooting
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4.4 Turning the differential locks off

CAUTION
Danger of damage to drive axles as well as the entire drive train!
Considerable damage can be caused by driving on solid, tractive ground with a good grip with added
differential lock.
Turn the differential locks off again as soon as possible.

Turning off the longitudinal differential lock automatically turns off any transversal differential locks that
are active.
Result:
– The function controls on button 138, button 140 and button 141 go out.
– All differential locks are turned off.

Result:
– Transversal differential lock axle 1 (with 10x8 drive)* + axle 2 is turned off.

Result:
– Longitudinal differential lock axle 4 + transversal differential lock axle 4 + axle 5 is turned off.
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5 Steering
There are 6 operating modes for steering the crane:
1.) Road driving, illustration 1
2.) All-wheel steering, illustration 2
3.) Crab steering, illustration 3
4.) Reduced swing-out rate, illustration 4
5.) Independent steering, illustration 5
Note
On public roads!
Only drive in “Road driving” mode on public roads.
5.1 General
DANGER
Danger of crushing!
Ensure no one is between the wheels when the engine is started and a gear is selected.
Approval to shift change between the individual operating modes is checked each time by the system.
If a shift is not permitted, an acoustic signal will sound and an operating error message (LEC) will be
shown on the display unit 225.
A change in operating mode is only possible up to a speed of 18 km/h. The operating mode can only
be activated if the wheels are in a position which permits a direct transition to the selected operating
mode.
When the power supply is turned on, the last selected operating mode is activated.
If the steering deflection of the wheels correspond to the selected operating mode, then the selected
operating mode is activated.
If the steering deflection of the wheels does not correspond to the last selected operating mode, then
the function check on the button for the last selected operating mode will blink. Operating mode
“Independent steering” is set. This means that the respective operating mode can be selected
indirectly.
From a temperature of -20 °C operate steering several times before driving off so that the oil in the
steering cylinders becomes warm.
Note
Steering at standstill!
To ensure steering of the electrically steered rear axles at a speed of less than 5 km/h, a hydro
accumulator is actuated and charged with pressurized fluid from the steering circuit II every time the
engine is started and subsequently periodically after every steering request. This can cause a short
term, slight increase of force on the steering wheel.
This procedure has no influence on the safety of the steering system, the steering system
continues to be fully functioning!
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242 LIEBHERR 3.04

5.1.1 Limiting the speed in the event of defects in the active rear axle steering
If a defect occurs in the steering, the maximum driving speed is limited to 40 km/h unless a restriction
of less than 40 km/h is already in effect and the vehicle is not moving at a speed of up to 40 km/h.
If a defect occurs while driving and the speed is greater than 40 km/h, the maximum speed is reduced
to the current driving speed. This means that the driver will be able to continue to drive at the current
speed until the speed is reduced. However, he can no longer accelerate. If a speed of 40 km/h or less
is reached the limit remains at 40 km/h. This is designed to ensure that the vehicle does not suddenly
lose power and therefore is suddenly slowed down.
5.1.2 Function controls

The function control on the button lights up.
Result:
– Operating mode is activated.
Function control on button does not light up.

Result:
– Operating mode is not activated.
Function control on the button blinks slowly.

Result:
– Operating mode has been selected, but has not yet been accepted by the control.
– The function control will continue to blink until it is possible to transfer to the operating mode.
Troubleshooting
The function control on the button for the active operating mode lights up, but the function control on
the button for the selected operating mode blinks slowly?
The selected operating mode does not correspond to the active operating mode because the control
has not (yet) approved the change.
Move the wheels into a position that will permit a change.
Or select operating mode indirectly.
Troubleshooting
The function control on the button blinks fast?
There is a defect in the steering system. The operation of the button will be suppressed and an
acoustic signal or an error message will be indicated on the display unit 225 if necessary.
Remedy the error.
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244 LIEBHERR 3.04

5.1.3 Control lights

The control light 181 shows the condition of the steering:
– The control light 181 lights up: Steering ok.
– The indicator light 181 blinks fast: Error in steering system with error code.
– The indicator light 181 blinks slowly: Error in the LSB bus connection.
DANGER
Risk of accident!
An error in the steering will be indicated by the blinking control light 181 and fast blinking of all 6
buttons for the steering operating modes. An acoustic warning signal also sounds every 3 seconds.
The rear steering axles are automatically centred back to the 0° position. If the vehicle is cornering at
this time, this action will only take place when the crane changes direction. The turning radius of the
crane will be greater due to the 0° position of the rear steering axles.
Changing operating modes is no longer possible.
Ensure that only a short distance is driven at a reduced speed and bring the vehicle to a stop as
quickly as possible.
Have problems remedied immediately by authorized, trained expert personnel!
Set the ignition to “ON”.

Result:
– A light test will be carried out on the display unit and the keyboard.
– The control light 181 “Steering” will be off for a short period.
Note
If no defect in the “active rear axle steering” is signalled at the keyboard or display unit the crane
may be driven.
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5.2 Changing between operating modes
5.2.1 Direct selection

Select the desired operating mode using the button 143 and the operating mode button. Turn the
steering wheel until the wheels on the front axles go through the 0° position. The wheels of the rear
axle will be automatically aligned. When the desired operating mode has been achieved the control
light on the operating mode button will remain continuously illuminated.
5.2.2 Indirect selection using the operating mode “Independent steering”

The operating mode can also be changed without changing the current steering effort of the wheels
on the front axle. To do this, first select the operating mode “Independent steering”. When the
“Independent steering” operating mode has been accepted, the button 143 and the desired operating
mode button must both be pressed until the wheels of the rear axles have achieved their specified
position. When the desired operating mode has been achieved the control light on the operating mode
button will remain continuously illuminated.
5.3 On road driving
The “Road driving” operating mode is the default setting. In this mode, the rear steering axles are
steered depending on the steering of the front axles. The steering angle reduces as the vehicle
accelerates. Steering axles 3 and 4 are moved back to the 0º position when the speed reaches
30 km/h. Steering axle 5 is moved back to the 0º position when the speed reaches 60 km/h.
5.4 All wheel steering
In the “All-wheel steering” operating mode, the rear steering axles are steered dependent on the
steering effort of the front axles so that the vehicle attains as small a turn as possible.
The maximum driving speed is limited to 20 km/h.
3.04 LIEBHERR 247

5.5 Crab steering
In the “Crab steering” operating mode, the rear steering axles are steered in the same direction as the
front axles. The maximum steering effort of the rear steering axles is restricted by the maximum
steering effort of the 1st rear steering axle.
The wheels could grind if the front axles are locked harder than the maximum possible angle of the
rear steering axles. This is also dependent on weight distribution of the crane.
5.6 Reduced swing-out rate
In the “Reduced swing-out rate” operating mode, the rear steering axles are locked in dependence on
the front axles so that the swing-out rate of the vehicle rear-end is reduced to a minimum. This
operating mode would typically be selected when driving away from the edge of a house.
Only restricted turns are possible in this operating mode.
5.7 Independent steering
248 LIEBHERR 3.04

In the “Independent steering” operating mode, the rear steering axles are steered independent of the
steering effort of the front axles using the key 117 and the key 118. The rear steering axles move
parallel, when the front axles and the rear steering axles all moved in the same direction. When they
are moved in the opposite direction, the steering axles are proportioned as for cornering. The
“Independent steering” operating mode can be enabled in all wheel positions.
3.04 LIEBHERR 249

B198122
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6 Towing
6.1 General towing regulations

The following towing regulations must be adhered to:
– For the towing procedure, release the parking brake or the brake system will be damaged.
– When towing, the speed must always remain below 20 km/h.
– Use the manoeuvring coupling to tow the vehicle.
– Only tow with a tow bar.
– Turn on the hazard warning system and the headlight.
– When towing always switch the transfer transmission to freewheel.
6.2 Towing with a defective engine and / or transmission

If the engine cannot be started, a pressurized air supply must be established from the towing vehicle
to the mobile crane. A hose coupling is attached at the front under the bumper to supply compressed
air to the mobile crane to be towed.
Use a hose line to connect the external supply with the towing vehicle.
DANGER
Risk of accident!
The supply pressure of the compressed air brake system of the mobile crane to be towed must be
at least 6 bar.
With the engine turned off the vehicle can only be steered from a speed of 5 km/h - 10 km/h.
Actuate the switch 50 and shift the transfer transmission to freewheel.

Using the travel range switch 101, switch the gear box to the neutral position “N”.
6.3 Towing with an intact engine
6.3.1 Towing in case of damage on the transfer transmission

Disconnect the drive shafts from the distributor gear to the drive axles on the drive axles and tie
them up.
Using the travel range switch 101, switch the gear box to the neutral position “N”.
Let the engine run at low idle speed.
6.3.2 Towing in case of damage to the drive axles

Only authorized and specially trained personnel can carry out towing arrangements in case of
damage to the driving axles.
Assign specially trained personnel to carry out this work.
6.4 Extended manoeuvring coupling*

Note
Only the hook block may be engaged on the extended manoeuvring coupling* to move the crane
vehicle. If the crane vehicle is towed, the manoeuvring coupling without extension must be
assembled on the crane vehicle.
The tightening torque for the mounting screws of the manoeuvring coupling is 540 Nm.
Remove the extended manoeuvring coupling*.

Remove extension on manoeuvring coupling.
Assemble the manoeuvring coupling without extension on the crane vehicle.
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026704-00 3.05 Crane at the job site
B198125
252 LIEBHERR 3.05

3.05 Crane at the job site 026704-00
1 General
1.1 Selecting the location

Note
Chapter 2.04, “Technical safety instructions” must be observed and complied with.
Support basis
reduced 8.8 m x 5.5 m
wide 8.8 m x 8.3 m
Select crane operating location where the supports can be extended to provide the support
specified in the load charts and the crane can be levelled.
1.2 Convert from driving mode to crane operation

Ensure that the following prerequisites are met:
– the crane is on a level and load-bearing surface
– the parking brake is applied
– the manual transmission is in neutral position “N”
1.2.1 Locking the axle suspension

The axle suspension must be locked before the crane is supported.
Result:
– Function control on button 130 illuminates.
– Axle suspension is locked.
Extend support cylinders and sliding beams.
1.2.2 Converting to crane operation

– the engine is turned off
– the ignition is turned off
– the axle suspension is locked
If the rotary switch 34 is operated while the engine is running, the engine shuts off automatically.
If the rotary switch 34 is switched to superstructure operation, the engine can no longer be started
from the support control units. Changing the RPM on the support control units is also no longer
possible.
Turn the rotary switch 34 to the left to the symbol “Crane operation”.
Result:
– The crane has been switched to superstructure operation.
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1.3 Moving the support pads from transport position (illustration 1) to

operating position (illustration 2)
Remove spring-loaded safety pin 5 of socket pin 3.
Withdraw socket pin 3 from hole 2.
Pull support pad outwards using handle until socket pin 4 meets ball head of support cylinder.
Insert socket pin 3 into hole 1 and secure with spring-loaded safety pin 5.
1.4 Moving the support pads from operating position (illustration 2) to

transport position (illustration 1)
Remove spring-loaded safety pin 5 from socket pin 3.
Withdraw socket pin 3 from hole 1.
Use handle to slide support pad until it meets ball head of support cylinder.
Insert socket pin 3 into hole 2 and secure with spring-loaded safety pin 5.
1.5 Support pads, illustration 3

Observe the safety instructions and permissible ground pressures (see Chapter 2.04).
Support pad area = 3600 cm2
DANGER
Risk of accident!
Always put suitable materials beneath the support pads.
Place the bases beneath the centre of the support pads.
Place stable materials such as wood, steel plates or concrete slabs of a suitable size beneath the
supports pads, depending on the ground conditions.
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1.6 Converting from crane operation to driving mode

– the crane is supported and level
– the wheels are not in contact with the ground
– the telescopic boom is fully telescoped in
– the telescopic boom is locked to the boom support at the front
– the manual transmission is in neutral position “N”
1.6.1 Switching the axle locking off
WARNING
Risk of damage to axle suspension!
If the axle block is turned off without the wheels being in contact with the ground, then the axle
suspension can be damaged if the axles drop down.
Do not switch axle locking off until all wheels are in contact with the ground.
Retract support cylinders until all wheels are in contact with the ground.
Result:
– The function control on the button 130 goes out.
– The axle suspension is active.
Retract the support cylinders and the sliding beams all the way.
1.6.2 Converting to driving mode

– the engine is turned off
– the ignition is turned off
Turn the rotary switch 34 to the right to the symbol “Driving mode”.
Result:
– The crane is switched to driving mode.
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2 Support control unit
2.1 General
The crane may be supported by support control units on the chassis as well as from the cab of the
crane.
An support control unit (switch box) with buttons is attached to both sides of the vehicle for operating
the support.
DANGER
Danger of fatal injury!
The crane operator must set the LICCON overload protection in accordance with the load chart for
the respective support width.
The support cylinders must be on a base in accordance with specifications.
Turn the ignition on.

Press support control unit release 269.
Result:
– All buttons and the green LED 277 “Support control unit release” illuminate.
– The support control unit is activated.
– The release goes off if no other key is pressed for 120 s or if the support control unit release 269 is
pressed again.
– Deactivation of the support control unit is indicated by the button flashing and the green LED
277 going off.
The engine can be started using the button 274 or turned off using the button 273. The engine
RPM can be varied during the supporting procedure using the button 276 and the button 275.
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2.2 Extending the sliding beams with support control unit

The sliding beams on the left side of the vehicle can only be operated using the support control unit
attached at this side.
The sliding beams on the right side of the vehicle can only be operated using the support control unit
attached at this side.
DANGER
Danger of fatal injury when extending and retracting the sliding beams!
The operator must monitor the extension and retraction of the sliding beams.
Make sure that there are no persons or objects within the danger zone when extending or
retracting the sliding beams.
Remove retaining pins 1 from the sliding beams.

Remove the retaining pins 1a at the “right rear” sliding beam.
Note
When the sliding beam extends, the inner beam is first completely extended before the outer
beam is extended.
Extend sliding beams to the support basis specified in the load chart:
Left support control unit: Press button 254 and button 256.
Right support control unit: Press button 284 and button 286.
DANGER
Risk of accidents if the crane topples over!
The crane may topple over if the following conditions are not met.
The sliding beams must be pinned to prevent movement of the bearing surfaces after positioning!
Pin in and lock all retaining pins.
Do not support in intermediate positions!
Secure and lock sliding beams with retaining pins 1 and retaining pins 2.
Note
Use retaining pin 1a instead of retaining pin 1 to pin the “right rear” sliding beam.
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2.3 Extending support cylinders with support control unit

DANGER
Danger of accident when supporting!
Ensure that there are no persons or objects present in the danger zone when the support
cylinders are being extended and retracted.
Raise the crane until the wheels are no longer touching the ground.
Do not extend the support cylinders all the way during crane operation (up to stop position)! If
support cylinder has been moved out all the way, retract again by at least 10 mm.
Ensure that the crane has been lifted so that the wheels are no longer touching the ground.
2.3.1 Supporting manually

Supporting the crane
Extend individual support cylinders evenly by pressing the relevant buttons and support the crane.
The support cylinders initially move at minimum speed and accelerate to maximum speed after 2.5 s.
Left support control unit: Press button 251, button 253, button 259 and button 261.
Right support control unit: Press button 281, button 283, button 289 and button 291.
Aligning the crane horizontally
DANGER
Crane can topple over!
If the crane is not aligned horizontally, it may tip over and cause fatal injury!
Be sure to level the crane!
The maximum permitted deviation from the horizontal position is 0.5 % ( 0.3°)!
Extend and retract individual support cylinders until the innermost light emitting diode (LED) lights
up.
Result:
– The crane is horizontal.
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2.3.2 Supporting automatically
DANGER
Risk of accident!
When the automatic support is operated the crane is levelled automatically.
Ensure that the alignment is within the permitted tolerance and that all four support pads are
touching the ground.
As long as the chassis is leaning (5° range) the support cylinders are actuated at approximately
three-quarter speed. The speed is reduced to 50% when the 1° range is reached.
Press button 272.
Result:
– All support cylinders are extended.
– The crane is levelled.
2.3.3 Checking supports

In order to minimise the accident risk the extending distances and the following safety regulations
must be adhered to.
DANGER
Danger of fatal injury if crane falls over!
The load suspended on the hook causes tension and deformation of the hoist rope and telescopic
boom (also applies to auxiliary boom and stay ropes, if used). If the load is dropped or a stay rope or
hoist rope breaks in this situation, the crane is suddenly unloaded. The boom snaps back. If only the
sliding beams at the load side are extended the crane could tip over.
Another situation may occur when it becomes necessary to slew the load to the opposite side. If only
the sliding beams on the load side are extended the crane could tip over.
When rotating out of the longitudinal vehicle direction, the boom or counterweight force could tip over
the crane unless all four sliding beams are extended.
Always extend all 4 sliding support beams, i.e. also on the side opposite the load.
Check beam extension situation.

Make sure that all four sliding support beams have been extended.
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2.4 Retracting support cylinders with support control unit

DANGER
Danger of injury when extending and retracting the support cylinders!
Ensure that there are no persons or objects in the danger zone.
Start the engine.
Evenly retract the support cylinders by pressing the relevant buttons until the wheels are touching the
ground.
Left support control unit: Press button 250, button 252, button 258 and button 260.
Right support control unit: Press button 280, button 282, button 288 and button 290.
or
If all support cylinders are to be retracted together:
Press button 271 until all wheels are in contact with the ground.
WARNING
Press button 130 and button 143 and switch off axle locking.
Retract all four support cylinders all the way.
2.5 Moving and securing the support pads to transport position

Move support pads to transport position and secure.
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2.6 Retracting sliding beams with support control unit

The sliding beams on the left side of the vehicle can only be operated using the left support control
unit.
The sliding beams on the right side of the vehicle can only be operated using the right support control
unit.
DANGER
Danger of injury when extending and retracting the sliding beams.
Only operate the sliding beams that you can see.
Ensure that there are no persons or objects in the danger zone.
Unpin retaining pin 1 and retaining pin 2.

Place retaining pins 2 in the relevant deposit locations.
Note
When the sliding beam retracts, the outer beam is first completely retracted before the inner beam
is retracted.
Left support control unit: Press button 255 and button 257.
Result:
– The sliding beams at the left side of the vehicle are retracted individually.
Right support control unit: Press button 285 and button 287.
Result:
– The sliding beams at the right side of the vehicle are retracted individually.
Secure sliding beams with the retaining pins 1 and lock.
Note
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B198130
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2.7 Switching the sliding beam illumination on

Sliding beam illumination is blocked at a speed of greater than 3 km/h.
The sliding beam illumination is also switched off and blocked if the engine is turned off. However,
“Automatic sliding beam illumination active/inactive” status is noted.
2.7.1 Manual
– the engine is ON
– the vehicle is stationary
Press key 164 on the keyboard.
Result:
– Sliding beam illumination is switched off or on.
2.7.2 Automatic
– the vehicle is in support mode (transmission in neutral “N” and key pressed on the support control
unit)
Press any key on the support control unit.
Result:
– The sliding beam illumination is switched on.
Troubleshooting
Can sliding beam illumination not be switched on automatically?
If sliding beam illumination has been automatically switched on and then switched off in the chassis
using the key 164 on the keyboard, automatic sliding beam illumination has been deactivated.
Switch sliding beam illumination on again using the key 164 on the keyboard. Automatic sliding
beam illumination is active again.
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3 The “Support” program
3.1 General
The supports are operated from the crane cabin using the LICCON monitor. Also refer to chapter
4.02, paragraph “Support program”.
The “Support program” may also be used to work and operate the crane. Support operations that
must be repeated at short intervals do not require switching back to the “Operation program”.
DANGER
Danger of injury if hazard warnings are ignored!
An increased accident hazard exists, if the following hazard warnings are not observed!
All regulations and hazard warnings listed in paragraph “Support control unit” must be observed!
The operator must monitor the extension and retraction of the sliding beams.
A guide is required to assist when extending and retracting the supports without any visual contact
with the support cylinder or sliding beam.
Exercise caution to make sure no persons or objects are in the danger zone when extending and
retracting the sliding beams.
The crane must be levelled.
All 4 sliding beams and support cylinders must be extended, the ones on the side opposite the
load as well.

– the crane is on a level and load-bearing surface
– the telescopic boom is telescoped in all the way and put into the boom support
– the parking brake in the driver cab and the crane cab is closed
– the retaining pins 1 or retaining pin 1a and retaining pins 2 on the four sliding beams are unpinned
– the rotary switch 34 has been moved to crane operation
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3.2 Extending sliding beams from the crane cab

DANGER
Danger of fatal injury if crane falls over!
Always extend all 4 sliding support beams, i.e. also on the side opposite the load.
Only one sliding beam may be extended at a time.

Press function key F7 7 and select the desired sliding beam.
Result:
– Selector (double arrow) appears on the selected sliding beam.
Note
When the sliding beam extends, the inner beam is first completely extended before the outer
beam is extended.
Press function key F5 5 and extend the sliding beam to the required support base.
Extend all sliding beams to the required support bases.
DANGER
Risk of accidents if the crane topples over!
The crane may topple over if the following conditions are not met.
The sliding beams must be pinned to prevent movement of the bearing surfaces after positioning!
Pin in and lock all retaining pins.
Do not support in intermediate positions!
Secure and lock all sliding beams with retaining pins 1 and retaining pins 2.
Note
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3.3 Extending support cylinders from the crane cab

DANGER
Danger of accident when supporting!
Ensure that there are no persons or objects present in the danger zone when the support
cylinders are being extended and retracted.
Raise the crane until the wheels are no longer touching the ground.
Do not extend the support cylinders all the way during crane operation (up to stop position)! If
support cylinder has been moved out all the way, retract again by at least 10 mm.
3.3.1 Supporting manually

Up to 4 support cylinders may be extended at the same time.
Select the appropriate support cylinder using the numeric keyboard 1 - 4.
Result:
– Selector(s) appear or disappear on the selected support cylinders.
Press function key F3 3.

Result:
– All pre-selected support cylinders are extended.
3.3.2 Aligning the crane horizontally
DANGER
Crane can topple over!
If the crane is not aligned horizontally, it may tip over and cause fatal injury!
Be sure to level the crane!
The maximum permitted deviation from the horizontal position is 0.5 % ( 0.3°)!
Extend and retract individual support cylinders until the point (small square) is in the centre of the
graphic spirit level.
Result:
3.3.3 Supporting automatically
DANGER
Risk of accident!
When the automatic support is operated the crane is levelled automatically.
Ensure that the alignment is within the permitted tolerance and that all four support pads are
touching the ground.
Press the SHIFT key 10 and function key F3 3.

Result:
– All support cylinders are extended.
– The crane is levelled.
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3.4 Retracting support cylinders from the crane cab

Up to 4 support cylinders may be retracted at the same time.
Select or deselect the relevant support cylinders using the numeric keypad 1 - 4.
Result:
– Selector(s) appear or disappear on the selected support cylinders.
Operate function key F4 4 and retract the preselected support cylinders until the wheels of the
crane contact the ground.
or
Press the SHIFT key 10 and function key F4 4 and retract preselected support cylinders until the
wheels of the crane contact the ground.
WARNING
Press button 130 and button 143 and switch off axle locking.
Retract all four support cylinders all the way.
3.5 Moving and securing the support pads to transport position

Move support pads to transport position and secure.
3.6 Retracting sliding beams from the crane cab

Only one sliding beam may be retracted at a time.
Unpin retaining pin 1 and retaining pin 2.
Place retaining pins 2 in the relevant deposit locations.
Press function key F7 7 and select the desired sliding beam.
Result:
– Selector (double arrow) appears on the selected sliding beam.
Note
When the sliding beam retracts, the outer beam is first completely retracted before the inner beam
is retracted.
Press function key F6 6 and completely retract the sliding beam.

Completely retract the 4 sliding beams.
Secure all sliding beams with the retaining pins 1 and lock.
Note
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3.7 Switching the sliding beam illumination on

Sliding beam illumination is blocked at a speed of greater than 3 km/h.
The sliding beam illumination is also switched off and blocked if the engine is turned off. However,
“Automatic sliding beam illumination active/inactive” status is noted.
3.7.1 Manual
Result:
– Sliding beam illumination is switched off or on.
3.7.2 Automatic
Press any support function.
Result: The sliding beam illumination is switched on.
Troubleshooting
Can sliding beam illumination not be switched on automatically?
If the sliding beam illumination has been automatically switched on and then switched off using
function key F2 2 or is switched off with the key 164, the automatic switching on of the sliding beam
illumination is deactivated.
Switch sliding beam illumination on again using the function key F2 2 or the key 164. Automatic
sliding beam illumination is active again.
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4 Before leaving the work site
4.1 Checks to be performed

After a longer period of time on the construction site, all the checks described in Chapter 3.02 must be
carried out before starting to drive.
DANGER
Risk of accident if crane is not in a suitable condition for transportation!
Locking mechanisms, spring-loaded safety pins and retaining pins must be fitted and secured to
prevent them from becoming loose during the journey and causing damage.
Perform the following checks before leaving the work site:

Check that the axle suspension is switched on.
Check whether the support cylinders are fully retracted.
Check whether the support pads are in transport position and have been secured 5.
Check whether the sliding beams have been fully retracted and pinned 1/1a.
Check whether the retaining pins 2 have been secured in their holders.
Check whether the chocks are in their holders.
Check whether the telescopic boom has been retracted and placed on the boom support.
Check whether the superstructure is locked to the chassis.
Check whether the turntable panels are locked.
Check whether the doors and windows of the crane cab are closed.
Check whether the footboard under the crane cab has been retracted and secured.
Check whether the folding ladder and cab have been correctly secured.
Check whether the spare wheel* has been properly secured.
Check whether the hoist rope has been hung up and fixed on the front towing coupling 7.
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4.00 Operation of crane superstructure
LIEBHERR 285
028411-00 4.01 Operating and monitoring instruments on the crane superstructure
B196007
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4.01 Operating and monitoring instruments on the crane superstructure 028411-00
1 Operating and control instruments
1.1 General operating elements

300 Armrest
301 Seat contact switch
302 Manual lever • Adjustment of seat cushion angle
303 Button • Lumbar support in lower part of backrest
304 Button • Lumbar support in upper part of backrest
305 Manual lever • Lock for horizontal seat adjustment
306 Manual lever • Backrest incline adjustment
308 Rotary switch • Switching between fresh air / recirculated air
309 Rotary switch • Blower 3-stage
310 Regulator knob • Temperature Cab heater
311 Socket, 24 V
312 Cab lighting
313 Lock • Step retainer
Pull handle and hold: Step unlocked
Release and engage the handle: Step locked
314 Reservoir • Windshield washer fluid
315 Charge indicator light • Superstructure engine
316 Indicator light • Superstructure engine preheating, heat flange control
317 Charge indicator light • Chassis engine
318 Indicator light • Chassis engine preheating, flame starting system
319 Ignition starter switch • Chassis engine
320 Ignition starter switch • Superstructure engine
321 Thermostat* • Auxiliary heater
322 Battery master switch
323 Lock screw • Adjusting the control platform in lengthwise direction
324 Switch* • Seat heater
325 Set screw • Adjustment of armrest incline
326 Locking lever • Armrest height adjustment
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1.2 Control elements Roof console

335 Key switch* • Turn radio remote control on / off
340 Indicator light • Central lubrication
341 Operating hour meter -
Superstructure
342 Indicator light* • Air conditioning system is turned on
343 Indicator light • Tele pinning
Note:
The control light 343 tele pinning is only needed when the
telescopic boom has to be manually pinned.
345 Switch • Instrument panel illumination
346 Switch • Extend / retract the step
Actuated on top: The step is extended.
Actuated on the bottom: The step is retracted.
347 Switch* • Aircraft warning light, on the boom head or the single and
double folding jib
348 Button* • Height adjustment working floodlight, boom pivot section
349 Switch* • Working floodlight on the boom pivot section
350 Switch* • Working floodlight on the boom pivot section or the boom head
351 Switch* • Working floodlight, cab roof rear and front
352 Switch • Working lights headlight for winch and mirror heater
353 Switch • Working floodligh on cab front
354 Switch* • Air conditioning system
355 Indicator light* • Auxiliary heater turned on
356 Switch* • Auxiliary heater
357 Sign • Function of 2 positions of switch 358 in emergency operation
358 Button • For emergency operation, with 2 switch positions
• Position 2 (actuated on top):
• Hoist up
• Turn to left
• Telescope the telescope in
• Luff the boom up
• Position 0 (center position):
• Off
• Position 1 (actuated on the bottom):
• Hoist down
• Turn to right
• Telescope the telescope out
• Luff the boom down
359 Switch • Manual pressure boost for emergency operation
360 Switch • Manual telescoping.
• Position 2 (actuated on top): Unpin telescope
• Position 0 (center position): Pin the telescopic boom, lock the
telescoping cylinder
or automatic telescoping.
• Position 1 (actuated on the bottom): Unpin the telescoping
cylinder
361 Sign • Function of 3 positions of switch 360
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362 EMERGENCY OFF

switch
363 Indicator light • Pressure supply during telescope disassembly
364 Switch • Addition of pressure supply during tele disassembly
365 Button • Windshield washer system front window
366 Switch • Window wiper - front window, 2 stages: 1 intermittent, 2 wipe
367 Button • Windshield washer system - roof window
368 Switch • Windshield wiper - roof window, 2 stages: 1 intermittent, 2 wipe
369 Switch • Crane superstructure locking
370 Indicator light • Raise / lower counterweight
372 Timer for auxiliary With the following displays:
heater* • Time and day of the week
• Fault in auxiliary heater
• Air temperature
• Preselection of heater operation
374 Pedal • Slewing gear brake
375 Foot button • Coasting slewing gear
377 Pedal • Engine regulation, superstructure engine
378 LICCON monitor
379 Buzzer • Counterweight up / down
390 EMERGENCY OFF
switch*
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1.3 Operating elements on control console (machines with one winch)

Control console, left:
400 Master switch left (MS 2) Telescoping gear
• Move the master switch 400 in direction Y+ (forwards):
Telescope out
• Move the master switch 400 in direction Y- (backward):
Telescope in
Slewing gear:
• Move the master switch 400 in direction X+ (to the right): The
slewing gear turns to the right.
• Move the master switch 400 in direction X- (to the left): The
slewing gear turns to the left.
401 Button • Bypass of the seat contact switch Or if the seat contact switch
is actuated: Addition of the vibration sensor 403
402 Button • Addition of the rapid gear for winch 1 and luffing up
403 Vibration sensor • Winch turn sensor, (vibrator) winch 1
404 Button • Lock the engine regulation of superstructure engine
Note:
Pressing the button 404 will lock the engine regulation in its
current position.
405 Button • Horn
410 Switch • Swing the crane cab
• Position 2 (actuated on top): The crane cab swings down.
• Position 0 (center position): Off
• Position 1 (actuated on the bottom): The crane cab swings up.
411 Button • Turn the “slewing gear parking brake” off / on
412 Button • Bypass of overload protection is used to luff in with suspended
load
DANGER
The exceedance may only be carried out if the overload
has been caused by luffing down at freely suspended load
and the crane operator is absolutely certain that he can
leave the overload range by luffing up.
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Control console, right:

420 Master switch - right Winch 1:
(MS 1) • Move the master switch 420 in direction Y+ (forwards): Winch 1
spools out and the load is lowered.
• Move the master switch 420 in direction Y- (backward): Winch
1 spools up and the load is raised.
Luffing the telescopic boom: Switch 430 in left position:
telescopic boom is luffed down.
telescopic boom is luffed up.
Luffing the auxiliary boom*: Switch 430 in right position:
folding jib is luffed down.
folding jib is luffed up.
422 Button • Addition of the rapid gear for winch 1 and luffing up
423 Button • Horn
Note:
current position.
430 Switch • Operating mode preselection for master switch 420
• Left position: Luffing the telescopic boom
• Right position: Luffing the auxiliary boom
431 Switch • Turn the acoustic warning (bell on turntable) off
433 Switch • Stand-by mode
Note:
Pressing the button 433 will turn off the superstructure engine,
but the LICCON will remain turned on.
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1.4 Operating elements on the control console (cranes with two

winches)*
Control console, left:
400 Master switch left (MS 2) Winch 2
• Move the master switch 400 in direction Y+ (forwards): Winch 2
Slewing gear:
slewing gear turns to the right.
slewing gear turns to the left.
402 Button • Addition of the rapid gear for winch(es) and luffing up
403 Vibration sensor • Winch turn sensor, (vibrator) winch 2 or turn sensor, (vibrator)
slewing gear
Note:
current position.
405 Button • Horn
410 Switch • Swing the crane cab
• Position 2 (actuated on top): The crane cab swings down.
• Position 0 (center position): Off
• Position 1 (actuated on the bottom): The crane cab swings up.
411 Button • Turn the “slewing gear parking brake” off / on
412 Button • Bypass of overload protection is used to luff in with suspended
load
DANGER
The exceedance may only be carried out if the overload
has been caused by luffing down at freely suspended load
and the crane operator is absolutely certain that he can
leave the overload range by luffing up.
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Control console, right:

420 Master switch - right Winch 1:
(MS 1) • Move the master switch 420 in direction Y+ (forwards): Winch 1
Telescoping gear: Switch 430 in left position:
• Move the master switch 420 in direction X+ (to the right):
Telescope out
• Move the master switch 420 in direction X- (to the left):
Telescope in
Luffing the telescopic boom: Switch 430 in center position:
telescopic boom is luffed down.
telescopic boom is luffed up.
Luffing the auxiliary boom*: Switch 430 in right position:
folding jib is luffed down.
folding jib is luffed up.
422 Button • Addition of the rapid gear for winch(es) and luffing up
423 Button • Horn
Note:
current position.
430 Switch • Operating mode preselection for master switch 420
• Left position: Telescoping gear
• Center position: Luffing the telescopic boom
• Right position: Luffing the auxiliary boom
431 Switch • Turn the acoustic warning (bell on turntable) off
433 Switch • Stand-by mode
Note:
Pressing the button 433 will turn off the superstructure engine,
but the LICCON will remain turned on.
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4.02 LICCON computer system 028412-00
1 General
Note
Note
The monitor illustrations in this chapter are only examples. The numerical values in the individual
icons and charts do not have to necessarily match the crane exactly. In addition, many of the
illustrations show the maximum configuration of the LICCON monitor with icons. In normal crane
operation, an identical display will not appear on the LICCON monitor.
The LICCON computer system is a computer system for controlling and monitoring mobile cranes. In
addition to the overload protection (Load moment limitation = LMB) there are a number of application
programs that can be used for controlling and monitoring the crane movements.
Currently the LICCON computer system includes the following application programs:
– “Configuration” program
– “Operation” program
– “Telescoping” program
– “Support* ” program
– “Working range limiter* ” program
– “Control parameter” program
– “Engine monitoring” program
The electrical and electronic components in the chassis and the superstructure are linked via
data bus transmission technology (Liebherr System Bus = LSB).
1.1 Overload protection (LMB)

The overload protection is implemented in microprocessor CPU 0 of base assembly 0. The LICCON
computer system works on the principle of comparing the current / actual load with the maximum
permissible load according to the load chart and reeving.
1.1.1 Actual load

The current load is determined by recording variable values.
The load on the crane results from the load momentum and the boom momentum together. It exerts
a force in the boom luffing cylinder, which is measured by pressure sensors.
The boom momentum is calculated with data from the angle sensors (boom angle), the length
sensors (boom length) and from crane data (boom weights) for the set operating mode.
The boom radius is calculated with data from the angle sensors (boom angle), the length sensors
(boom length) and from geometry data for the set operating mode. This also takes into account the
boom flexation due to its own weight and the weight of the load.
The actual load is calculated from the total load, the boom momentum and the boom radius.
1.1.2 Maximum load according to load chart and reeving

Crane data such as load charts, boom weights and geometry data are stored in the central data
memory of the LICCON computer system.
The “maximum load according to the load chart and reeving” is constantly determined for the set
crane configuration, for the set reeving and for the calculated radius, based on the load charts.
1.1.3 Comparison
The actual load and the “maximum load according to the loading chart and reeving” are compared.
When they approach the specified limit, an advance warning is issued. If this limit is exceeded, the
overload stop is triggered and any crane movements which increase the load momentum are turned
off.
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2 LICCON computer system boot up

After it is turned on, the LICCON computer system performs a self test.
First the connections from the microprocessor CPU (ZE 0) to the monitor are checked. If no error is
found during the test, the monitor shows this image:
If the test finds no connection problems, there is a system test of all the microprocessor CPUs (ZE).
The incremental sequence of the self test can be monitored on the 7 segment displays of the CPUs. If
no errors are found during the system test, the monitor shows this image:
Shortly after that, this general initialisation screen appears on the monitor:
Note
Errors during the boot up procedure of the LICCON computer system.
If an advance warning, warning or STOP event occurs in the engine monitoring section while the
LICCON computer system boots up, the system switches automatically to the “Engine
monitoring” program.
Refer to section “Engine monitoring program” for additional information.
If the start procedure has run successfully, it switches automatically to the “Configuration” program.
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2.1 Operating mode preselection on the LICCON computer system

DANGER
Risk of accident!
Only select the operating mode corresponding to the actual crane setup condition.
The operating mode preselection screen will appear on the monitor for approximately 3 s after
completion of the start up procedure and successful self-test of the LICCON computer system.
Note
Note
The operating mode preselection screen is skipped if the crane only has one level (for example:
only tele operation) - without optional equipment. In this case, the system changes directly into the
configuration screen for the only possible level.
If the memory loses its data (for example as a result of a cold start) the previous operating mode is
“rejected” and the first operating mode in the operating mode selection menu is activated. In this
case, the corresponding configuration screen appears.
When the operating mode preselection screen appears, press function key “F1” or “F2” within 3 s.
Result:
– The operating mode selection screen is retained until the settings are confirmed by pressing either
“F8” or “ENTER” .
Note
Note
If the crane operator does not press one of the two function keys “F1” or “F2” within 3 s, then
the system selects the operating mode which was active before the LICCON computer system
was turned off and the corresponding configuration screen appears automatically.
Press function key “F1” (cursor down) or “F2” (cursor up) to select the required crane operating
mode.
Note
Note
The selected operating mode is highlighted in black on the operating mode selection screen.
Press “F8” or “ENTER” .

Result:
– The selected operating mode is accepted by the LICCON computer system and the corresponding
configuration screen is displayed.
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3 Operating elements of the LICCON computer system

The functions of the individual monitor operating elements are program-dependent, and can differ,
depending on the LICCON program which is currently running. This will be described in more detail in
the description of the individual LICCON programs.
A Keypad
P Program keys • Selection of the individual LICCON programs
P0 Configuration • SHIFT and P0: Engine monitoring
P1 Operation
P2 Crane acceptance • Correction coefficients (for LIEBHERR personnel only)
P3 Support / stabilizers
P4 Telescoping
P6 Control parameter
P7 Working range
limitation*
P8 Test system
C Input key “ENTER” • Confirmation of changes
D Set up key • Position to right (touching)
= The hoist limit switch is bypassed and the load moment
limiter shut off has been exceeded.
Note:
By actuating the set up key D, all erection / take down
procedures can be carried out within the erection / take down
charts, for which no load charts are available!
• Operating position (self-retaining)
= Normal operation
E Special function keys • Monitor brightness adjustment
• E3 and E1: Turn background illumination on / off
• E3 and E2: Brightness adjustment in three stages
• Additional functions of the special function keys are
program-dependent and are further explained in the
descriptions of the individual LICCON programs.
F Function keys • The function keys should always be used in conjunction with
the function key icon line displayed on the monitor.
G Monitor • Display of the individual programs (example:
“Operation” program)
H SHIFT key • Second-level key assignments, for example “Supervisory
function”.
I LED displays • Monitor supply voltage present
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4 “Configuration” program
After turning the LICCON computer system on and after successful boot up, the
“Configuration” program appears automatically.
Note
Adjustment and display of equipment configuration and reeving.
Normally, the most recently run equipment configuration and the reeving used at that time will be
automatically set and displayed. Only when the computer system is started for the first time, or
after a loss of data occurred in the memory, for example a cold start (change of battery or CPU,
etc.), will the first valid configuration screen with the first valid operating mode and the reeving
number appear on configuration screen “0”.
Using the “Configuration” program, the crane operator can set the current operating mode, the current
configuration state of the crane and the reeving number of the hoist rope.
In addition, in the “Configuration” program he can also see all the load chart programmed into
LICCON.
4.1 Setting the operating mode and equipment configuration

The crane operator can select the operating mode and the equipment configuration using the function
keys or by entering a 4-digit short code.
Using the function keys:
The function keys are explained in the section “Function key line” in this chapter.
Select the respective function keys.
Press Enter key to confirm and accept the settings.
Result:
– The data from the selected load chart can be viewed.
Using a 4-digit short code:

Enter a 4-digit short code using the keypad on the LICCON monitor.
Press Enter key to confirm and accept the settings.
Result:
– The data from the selected load chart can be viewed.
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4.2 “Configuration” program areas

The monitor is divided into three areas in the “Configuration” program:
– General information line 1
– Display area of load chart values 2
– Function key line 3
Note
Note
icons and charts do not have to necessarily match the crane exactly. The programmed load charts
for the crane are binding.
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4.2.1 General information line

1 “Telescopic boom • The icon is identical for all operating modes.
length” icon
2 Abbreviations • For the programmed length units (LU) and weight units (WU)
Possible length units are [m] and [ft]
Possible weight units are [t] and [lbs]
3 4-digit short code • It is located next to the text “CODE” inside angled brackets
• Each short code uniquely identifies a crane configuration. The
valid equipment configuration and their associated short code
numbers for the crane can be found in the load chart manual of
the crane.
4 Organization number • For internal Liebherr load chart administration
5 Page number • Relates to the currently displayed part of the load chart
• Separated from the organization number with “.”
• The total number of pages in this load chart is in parentheses.
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4.2.2 Display area of load chart values

1 Telescopic boom lengths • In [m] or [ft]
Maximum of 7 columns per display page
• Displayed as the horizontal axis of the load value field
2 “Boom radius” icon • Operating mode dependent
• In [m] or [ft]
• Maximum 9 lines of radius values
• Vertical axis of load value field
3 Load value field • Columns under the telescopic boom lengths and in the lines to
the right of the radius values
• Load values depending on boom length and radius
4 Reeving number of hoist •* n *
rope n = Reeving number of the hoist rope between the boom head
and hook block, in order to be able to lift the maximum load in
the corresponding load chart column.
Note:
If a load value in the column exceeds that of a load that can be
lifted with the maximum possible reeving, then there is an
exclamation mark beside the reeving number (“!”). This
exclamation mark indicates that special equipment is needed to
lift this load.
5 Line for special displays • If a load chart consists of more than seven columns, it cannot
be fully displayed because of the size of the monitor. In that
case, marking arrows in the first or the seventh field indicate
that there are additional columns to the left or right of the
displayed chart. They can be shown by pressing the key E1 or
the key E2.
As supporting information, the currently selected column
number and the number of columns in the table are shown, for
example, 45 (89) corresponds with 45 of 89 columns.
• Note:
Using the key combination SHIFT and E1 or SHIFT and E2,
you can, where possible, scroll left or right by seven load chart
columns (corresponds to 1 page). The marking for selecting a
telescope target is placed in the center.
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6 Extension condition of • In percent [%]

telescopic sections • The first column contains the “boom length” icon [%].
Next to that are 5 lines for the extension condition of the
telescopic sections. The number in the icon column describes
the corresponding telescopic section (highest
number = outermost telescopic section). The value in the boom
length column displays the extension condition of the telescope
in percentages, which must be maintained for the
corresponding boom length.
The status indicator “+” next to the percentage boom status
value means that the corresponding telescopic section must be
pinned.
The status indicator “-” next to the percentage boom status
value means that the corresponding telescopic section can be
telescoped up as far as the percentage value of the boom
status under load (as in the load chart).
7 Mark for selecting • The special function key E1 or the special function key E2 can
telescope target be used to move the mark to the left or right (see chapter 4.05,
section “Telescoping”).
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4.2.3 The function key line

The function key line consists of function keys F1 to F8 and the function key icon bar above it. The
function keys correspond to the various function key icons above them.
Various functions are indicated by the function key icons, or they may refer to the following changes:
– Operating mode
– Set up condition
Not all function keys have to be assigned icons on the LICCON monitor. This depends on the program
selection.
Pressing a function key changes the appearance of the icon above, its meaning, or its textual content.
F1 Vertical paging • Depending on the size of the monitor, up to 10 load chart lines
can be displayed at once. If a chart consists of more than 10
lines, the display is spread over several pages. When pressing
a key, the next page of the load chart will be displayed, and the
number of the current page in the “general information line” will
be counted up by 1. When the last page is reached, page 1 will
appear again after pressing the function key F1.
F2 Main geometry status • Options for setting the different main boom operating modes of
the crane (if available). The types are described by
abbreviations and length data in the icon.
• Example:
T for Telescopic boom
SHIFT and F2 • Previous main boom (if present)
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F3 Accessories • Options for selecting the different accessory types of the crane
(if available). The types are described using abbreviations,
angle and length data in the icon.
• Example:
“K 0°” 22 m for the crane operation with folding
jib* assembled at an angle of 0° on the telescopic boom, length
22 m.
• Note:
Pressing the function key F2 and/or the function
key F3 removes all data related to the operating mode and
configuration state from the monitor and sets the short code in
the general information line to “CODE >????<”.
• Operating mode dependent data:
• Telescopic boom length icon for the general information line
• Length units and weight units
• Load chart organization number
• Boom radius icon
• Telescopic boom lengths
• Telescopic boom length icon in area “Extension status of
telescopic section in percentages [%]”
• Extension status of telescopic section with status indicator in
percentages
• Configuration dependent data:
• Numbering of current page number and total number of
pages in load chart
• Radius values in length units
• Load values in weight units
SHIFT and F3 • Previous accessory status
F4 Counterweight • Adjustment option for the current counterweight, which must be
on the superstructure in order to achieve the values in the
current chart. When pressing a key, the following icon appears
with additional text in the counterweight icon.
• Example:
“74 t ” = total counterweight of 74 t
F5 Support base • Adjustment option for support base. The supports must be
extended and pinned to the dimensions shown in the icon in
order to work with the current load chart.
• Example:
“8.88 m x 8.3 m ” = wide support base (= length x width)
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F6 Slewing range - • 360° working range: Unlimited rotation is possible.

Superstructure • 0° working range: Toward the rear (locked).
F7 Hoist rope reeving • Adjustment possibility for the number of hoist rope strands in
order to reach a particular load capacity.
The displayed number of hoist rope strands (reeving) in the
icon will be increased with every keystroke by one counter, up
to a fixed maximum value for the respective operating mode.
After that the counter restarts from a fixed minimum value.
If the set value is still within the minimum and maximum values
when switching to another operating mode, it remains valid.
Otherwise it will be set to the minimum value for the new
operating mode.
• After a “cold start” (for example, loss of data in the memory),
the display of the hoist rope reeving is at “0”.
SHIFT and F7 • Reduce the reeving number by 1
F8 Function key • Confirmation of selected equipment configuration
Prerequisites:
The configuration mode setting must be completed, i.e. a valid
short code is displayed and load capacity values are in the
chart field.
The external conditions for this configuration state, if specified,
must be fulfilled (e.g. locking the superstructure).
In the configuration state so far, the crane must not be loaded
to more than 20 %, and the load on the hook must not be
greater than 0.5 t. Switching to the “Operation” program can
otherwise only be done via the program key P1. In that case,
the newly entered equipment configuration is not accepted.
If the crane is equipped with sliding beam monitoring*, the
sliding beams must be extended to the support base specified
in the selected load chart.
If these preconditions are fulfilled, then the “O.K.” key confirms
the correctness of the chosen configuration state and the
selected reeving, and transfers the parameters to the
“Operation” program.
Note:
Make sure that after switching to the operating screen, the
chosen equipment configuration (short code) and the hoist rope
reeving(s) have been accepted.
• Display of operating errors from the “Configuration” program.
Operating errors caused by the “Configuration” program are
displayed in the icon above the function key F8 and in the error
line for about five seconds. If the function key F8 is pressed
within 5 seconds, the program will switch automatically to the
error determination screen in the test system and the error
documentary will be displayed. The operating error will not be
saved.
Operating errors are shown at the top of the error line.
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4.2.4 Other operating elements

A Keypad • Pressing the keypad deletes all operating mode and equipment
configuration dependent data from the monitor.
• The keys 0 to 9 on the keypad can be used to enter the short
code directly into the LICCON monitor.
• The key P and the key . have no function in the
“Configuration” program.
P Program keys • Selecting from the individual programs. The settings in the
Configuration program are discarded, and the equipment
configuration and reeving most recently confirmed with the
O.K. key will continue to be used.
A program currently running cannot be called again using its
program key.
C Input key “ENTER” • Confirmation of input both for short codes and for any change
in the equipment configuration using the function keys
• Key Enter after entering the short code, the code is searched
for in all stored load charts. If the matching load chart has been
programmed, it will be displayed in full. Otherwise there is an
error message in the form of “????” in the second part of the
organization number, and the acoustic signal “horn” sounds.
• Pressing Enter key after a changing the operating mode using
the function key F2 and the function key F3 searches for this
operating mode. If successful, sets its first equipment
configuration and displays the load chart and its short code. In
case of an error, the short code display remains at “CODE
????”, the organization number is displayed as “axxx???”, and
the acoustic signal “horn” sounds.
• Pressing Enter key after a change in the configuration status
using the function key F4, the function key F5 and the function
key F6, displays the load chart (if the chart exists) plus the
short code on the LICCON monitor. In case of an error, the
short code display remains at “CODE ????” and the acoustic
signal “horn” sounds.
D Set up key • Has no function in the “Configuration” program
E Horizontal paging • The E1 and E2 keys only have a function if this is indicated in
the “special displays line”.
If a load chart consists of more than seven columns, the first
display of the configuration state only shows columns 1 to 7.
The double arrow at the right edge of the line points to
additional columns in either direction. If the cursor touches an
edge with arrows, the next movement in this direction will
display the next three chart columns. The cursor will then be
automatically returned to the middle.
H SHIFT key • For example Supervisory function
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5 The “Operation” program

The LICCON program “Operation” assists the crane driver by displaying clearly on the monitor the
data needed for operating the crane. An acoustical signal accompanies all critical displays. Depending
on the equipment, a range of other icons may also be turned on as additional displays, either as
required by the crane operator or automatically in the event of a problem.
It also alerts the crane operator to imminent overload conditions. In the event of overload and many
error conditions, which could be hazardous, the system shuts off.
In the “Operations” program, the monitor is divided into six sections:
– Crane geometry and load information 1
– Alarm functions 2
– Special functions 3
– Monitored auxiliary functions 4
– Winch display 5
– Function key line 6
Note
Note
icons and charts do not have to necessarily match the crane exactly. The configuration of the
LICCON monitor with icons is only descriptive.
In actual crane operations, an identical icon display will not appear!
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5.1 Crane geometry and load information

1 “Maximum load” icon • In [t] or [lbs]
1.1 Reeving number of hoist • n = reeving number of hoist rope that is reeved at the pulley
rope head selected via the load chart (previously selected in the
“Configuration” program).
1.2 Maximum load according • In [t] or [lbs]
to load chart and reeving • It depends on:
• The selected operating mode
• The selected configuration (load chart)
• The boom radius
• The hoist rope reeving
• Note:
“? ? ? . ?” if a value in the load chart cannot be accessed, for
example because the crane is not within the load chart
range, or one or more sensors are missing or so defective,
so that the radius cannot be calculated.
2 Icon “Current load” • In [t] or [lbs]
2.1 Current load • Actual load display = load in [t] or [lbs] that is currently
suspended from the crane hook.
• Display of the calculated total load including the weights of the
support, the lifting and/or the fastening equipment
By using the function “Tare” (see description of function key
F7 in section “function key icon line”) the display can be
changed over to display the net load. In addition, the word
“net” appears in the icon, the unit of weight is then shown
directly next to the load icon.
• Note:
“? ? ? . ?” is displayed if one or more sensors are missing or so
defective that the current load cannot be calculated.
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3 “Dynamic utilization bar

display” icon
3.1 8-digit organization • Identifies the type of load chart that has been selected and the
number operating mode
3.2 Short code • Identifies the selected equipment configuration
3.3 Utilization scale • Marking from 90% utilization: Advance warning
• Marking at 100% utilization: STOP shut-off
3.4 Utilization bar of crane • According to load chart and reeving
3.5 Engine RPM • In [rpm]
• Note:
“????” is displayed for an invalid rotational value (for
approximately 10 seconds). A fixed RPM is set in the event of a
problem. The digital display blinks, and an error message is
displayed.
3.5.1 Engine RPM lock • The engine RPM can be locked on the master switch. If the
engine RPM has been locked, the icon “+” appears behind the
RPM display.
4 “Boom radius” icon
4.1 Radius • In [m] or [ft]
Identifies the horizontal center of gravity distance of the load
(on the load hook selected by the operating mode) from the
center of rotation of the superstructure, measured on the
ground. This also takes into account the boom flexation due to
its own weight and the suspended weight of the load.
• Note:
“? ? ? . ?” is displayed, if geometrical data or sensor values are
missing, so that the radius cannot be calculated.
4.2 Main boom angle to the • In [°]
horizontal • Note:
“? ? ? . ?” is displayed, when the geometrical data or the
sensor values are missing, so that the main boom angle cannot
be calculated.
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5 “Main boom length” icon

5.1 Length of main boom • In [m] or [ft]
5.2 Extension condition of • In [%]
individual telescopic Order: Telescope 1 to telescope 5 from left to right
sections
5.3 TELEMATIC • Special functions in “Operation” program
Note:
In the “Main boom length” icon all the information required is
displayed to enable an experienced crane operator to
telescope the telescopic boom to a desired length without
switching to the “Telescoping” program.
5.3.1 preselected telescoping
target reached
5.3.2 Nominal deflection • Request: Telescope in = down arrow
direction of master • Request: Telescope out = arrow up
switch
5.3.3 Error in system
6 “Pulley head height” icon
6.1 Pulley head height • In [m] or [ft]
• Identifies the vertical distance from the crane base to the
selected pulley head axle, to which the displayed maximum
load applies
• Note:
“? ? ? . ?” is displayed, when the geometric data or the sensor
values are missing, so that the pulley head height cannot be
calculated.
6.2 Angle of hydraulically • In [°]
adjustable folding jib • The display is in the form of the relative angle between the
(TNZK)* telescopic boom head and the folding jib.
• Note:
“? ? ? . ?” is displayed, when the geometry data or the sensor
values are missing, so that the angle of the hydraulically
adjustable folding jib cannot be calculated.
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5.2 Alarm functions

The limit ranges of the crane movements are monitored. The crane operator is alerted that the limits
have been reached when the following blinking icons are shown.
5.2.1 Boom limitation

2 “Boom limitation” icon • The luffing range of the boom is limited both upwards and
downwards. This icon appears if an end position determined by
the load chart is reached when luffing the boom or when luffing
up the boom is disabled by a proximity switch.
Shut off of upper / lower limit angle
2.1 Arrow pointing up • The arrow shows that the main boom was shut off because it
triggered the upper limit. During telescoping operation the
icon 2.1.1 is shown on the LICCON monitor.
If the folding jib is attached and configured, the arrow remains
unchanged however the icon 2.1.2 is shown on the LICCON
monitor.
Note:
Luffing down the main boom is still possible.
2.2 Arrow pointing down • The arrow shows that the shut off of the main boom was due to
triggering the lower limit. During telescoping operation the
icon 2.2.1 is shown on the LICCON monitor.
monitor.
Note:
Luffing up the main boom is still possible.
Shut off Steep boom*
2.3 Double arrow pointing up • The double arrow indicates that the proximity switch on the
turntable has shut off the main boom and folding jib. During
telescoping operation the icon 2.3.1 is shown on the LICCON
monitor.
monitor.
Note:
Luffing down the main boom is still possible.
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5.2.2 Hoist top limit switch HES1 and HES4*

3 “Hoist top on HES1 / • In order to prevent the crane from being operated without hoist
HES4* icons” limit switches (HES), the minimum hoist limit switch
configuration is continuously monitored. Four hoist limit
switches are possible.
An “operating error” is issued if a movement, which is shut off
by the hoist limit switch, is actuated anyway.
A “system error” is issued if a obligatory bus sensor is missing
or an active bus sensor is defective.
3.1 HES1 • Installation location: Telescopic boom head, right
Bus address: 28
Switch: -S930
• The icon appears if:
• The hook block moves against the HES1 on the right of the
telescopic boom head.
• HES1 is not active, although it must be present on the bus.
• HES1 has an internal error.
• Note:
The crane movements spool up hoist winch, luff down
telescopic boom and telescope out the telescopic boom are
shut off.
3.2 HES4* • Installation location: Telescopic boom head, left* or boom
nose*
Bus address: 24
Switch: -S931
• The hook block runs against the HES4 at the left telescopic
boom head* or on the boom nose*.
• Note:
shut off.
The HES4 must be plugged in in operation mode “Boom nose”.
3.3 HES1 and HES4* • The icon appears when icon HES1 3.1 and HES4 3.2 appear
simultaneously.
3.4 “Hoist top on boom • The icon appears when the “Hoist top shut off” is bypassed.
bypassed” icon
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5.2.3 Hoist top limit switch HES2* and HES3*

4 Icons “Hoist top at • In order to prevent the crane from being operated without hoist
HES2* / HES3* ” limit switches (HES), the minimum hoist limit switch
configuration is continuously monitored.
An “operating error” is issued if a movement, which is shut off
by the hoist limit switch, is actuated anyway.
A “system error” is issued if a obligatory bus sensor is missing
or an active bus sensor is defective.
4.1 HES2* • Installation location: Single folding jib* or auxiliary boom*
Bus address: 27
Switch: -S940
• The hook block moves against HES2 on the single folding
jib* or on the auxiliary boom*.
• Note:
shut off.
The HES2 must be plugged in in operation mode “Single
folding jib” or “Auxiliary boom”.
4.2 HES3* • Installation location: Double folding jib*
Bus address: 26
Switch: -S945
• The hook block runs against the HES3 on the double folding
jib*.
• Note:
shut off.
The HES3 must be plugged in in operation mode “Double
folding jib”. If this is not the case, an “LMB STOP” is triggered
and an operating error message is also transmitted.
4.4 “Hoist top on boom • The icon appears when the “Hoist top shut off” is bypassed.
bypassed” icon
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5.2.4 Load chart capacity, exceeded, Working range limitation*

5 “Advance warning” icon
5.1 Load chart utilization • The current load chart utilization is calculated from the “current
load” and the “maximum load according to the load chart and
the reeving”. The icon “Advance warning” appears, if the
current load chart capacity exceeds the (90 %) limit
programmed in for advance warning.
5.2 Engine monitoring • If a warning event occurs in the engine monitoring system, the
“Engine monitoring advance warning” icon is displayed on the
LICCON monitor.
6 “STOP” icon
6.1 Load carrying capacity • The “STOP” icon is displayed if the load chart load (“current
exceeded load” > “maximum load according to the load chart and the
reeving”) exceeds the 100 % mark.
• Note:
All crane movements that increase the load momentum are
shut off.
6.2 Engine monitoring • If a STOP event occurs in the engine monitoring system, an
automatic switch-over (from the program “Operation”,
“Support” or “Telescoping”) is activated into the program
“Engine monitoring”.
6.3 Working range • If a programmed working range limit* is reached, this condition
limitation* is indicated by the STOP icon Working range
limitation* 6.3 instead of the standard icon “LMB-STOP” 6.1 is
displayed.
Note:
If an LMB-STOP occurs simultaneously, the STOP Working
range limitation* 6.3 icon continues to be displayed. The
LMB-STOP is identifiable if the utilization bar exceeds 100 % or
if a maximum load carrying capacity of 0 t is permitted.
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5.2.5 Horn
7 “Horn” icon • Acoustical signal
• Sounds in addition to the optical display (for example, E:1TMS)
of detected operational errors, leading to interruption of a
movement, and application errors with error number (such as
sensor errors, which occurred due to insufficient sensor signals
or due to defective sensors).
“Horn” is a beeping sound of a duration of approximately 0.5
seconds, which is repeated in a second cycle.
• Operational errors are:
• Overload
• Boom outside the angle range of the load chart
• Boom outside radius range of the load chart
• Extension condition of telescopic sections not in accordance
with the load chart
• The following sensors are monitored:
• Hoist limit switch
• Length sensors
• Angle sensors
• Pressure sensors
• Wind sensor
• Battery voltage
• Inductive sensors
“Short horn” • Sounds in addition to the visual display of error messages
without an error number and which do not lead directly to crane
movement shut off by the LICCON overload protection.
“Short horn” is a beeping sound of a duration of approximately
0.1 seconds, which is repeated in a second cycle.
• The following errors are monitored:
• Maximum permissible wind speed exceeded (only for
activated wind sensor*)
• Maximum or minimum support force exceeded (only with
active support force monitoring*)
• Crane load value for “Caution” (90 %) reached.
Priority and “Horn off” • The “Horn” alarm has higher priority than the “Short
horn” alarm, i.e. “Horn” takes preference over “Short horn”.
• The “horn” as well as the “short horn” of the monitor may be
turned off by function key F8.
• If an operational error is present, press the function key
F8 again to automatically change into the error determination
screen of the test system. The error is displayed there in
documentary form.
• Note:
The “Horn”, as well as the “Short horn” immediately become
active again if an error recurs.
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5.3 Special functions

Note
The various icons 1 are shown only on a defined position on the LICCON monitor!
Only one icon at a time can be shown on the LICCON monitor!
5.3.1 Exceed shut off limits for overload protection / “Hoist top”
1.1 Exceed shut off limits for • The icon blinks:
overload protection / • When the overload protection is exceeded via the set up
“Hoist top” key D
Note:
The crane operation program is locked, meaning, no other
program can be turned on via the program keys.
or
• When the crane control is exceeded or bypassed in active
shut off (overload protection load moment limiter, “Hoist top”)
via the configuration button D
5.3.2 No load chart is available

1.2 No load chart is available • The icon blinks:
• When the crane control is bypassed in active shut off
(overload protection load moment limiter, “Hoist top”) via the
configuration button D and no load chart is available
Note:
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5.3.3 Fast mode (Rapid gear)

2 “Rapid gear” icon • The icon appears if rapid gear is enabled during a crane
movement.
• This is possible for the following crane movements:
• Lift / lower hoist gear 1
• Luff the boom up
• Note:
If a crane movement has reached its maximum speed due to
the current utilization, then no speed increase is possible by
adding the rapid gear.
If the total power requirement of all actuated crane
movements is larger than the available power, then those
crane movements are reduced which require the most
power.
If another crane movement is added or taken back to one or
more actuated crane movements then this has an influence
on the other movements. For that reason, we recommend in
situations in which an interference of the individual crane
movements is troublesome, not to add the rapid gear or to
turn the rapid gear off.
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5.4 Monitored auxiliary functions for crane operation

There are several monitored auxiliary functions, which can be displayed when needed or
automatically.
The monitoring of all auxiliary functions is always active, only the icons may be hidden. The icons of
the monitored auxiliary functions have their fixed place on the LICCON monitor.
Using the function key F3, you can show the icons for the monitored auxiliary functions. Since not all
icons of the auxiliary functions fit on one page (at maximum assignment), they are split over two
pages. The icons on page 2 (if available) can be shown with the function key F4.
Page 1:
Crane incline 1
Wind speed 2
Support force display 3
Slewing range 4
Telescopeable load 5
Page 2:
Not assigned
If an error occurs in one or more of these monitored functions, this is shown as follows in the
“Operation” program:
• Monitored auxiliary functions turned off F3:
• Error in one function on page 1:
Icon is displayed on page 1.
• Error in a function on page 1 and 2:
Icon is displayed on page 1 and icon for F4 blinks (= indicates an error in a function on page
2).
• Monitored auxiliary functions turned on F3:
• No error:
Optional icons (optional) are displayed.
If there are also optional icons on page 2, the icon “Change page” of the F4 key is activated (=
indication for switching option).
Icon has been previously displayed.
Icon “Change page” blinks (= indication regarding an error of a function on the other page).
• Error in a function on page 1 and 2:
Icon “Change page” blinks (= indication regarding an error of a function on the other page).
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1 “Incline” icon • Display of the incline of the superstructure to the horizontal in

longitudinal and lateral direction. The display is graphic as well
as numeric.
1.1 Graphic part • The graphic display is in the form of a spirit level, with a moving
dot (small square) representing the air bubble. The center of
the dot shows the precise incline value.
1.2 Numeric part
1.2.1 Incline range • Value either 1° or 5°
This value describes the resolution of the graphic illustration
and can only assume the two values “1°” or “5°”. If the incline is
less than 1° in lateral direction and in longitudinal direction, the
level moves within the 1° range. If at least one value exceeds
the 1° limit, it switches to the 5° range.
The range change is automatic.
1.2.2 Crane incline • In [°] in lateral direction
• The double arrow shows the direction of incline:
• Double arrow to left = crane is inclined to the left
• Double arrow to right = crane is inclined to the right
1.2.3 Crane incline • In [°] in longitudinal direction
• The arrow shows the direction of incline:
• Up arrow = crane is inclined to the rear
• Down arrow = crane is inclined to the front
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2 “Wind speed” icon • The wind speeds are displayed in [m/sec.] or [ft/sec.]
depending on the units of measurement shown in the load
chart.
2.1 “Wind speed” icon • In [m/s] or [ft/s]
2.2 current wind speed
2.2.1 Wind sensor (WS) 2 • Wind sensor 2 present:
(accessory) Telescopic boom head: no display
Accessories: current wind speed of WS2 is displayed
• Wind sensor 2 not present:
Telescopic boom head: no display
Accessories: “???” is statically displayed
2.2.2 Wind sensor (WS) 1 • Wind sensor 1 present:
(telescopic boom head) Telescopic boom head: current wind speed at WS1 is
displayed
Accessories: current wind speed at WS1 is displayed
• Wind sensor 1 not present:
Telescopic boom head: “???” is statically displayed by WS1
Accessories: “???” is statically displayed by WS1
2.3 Maximum permissible • With icon text “max:”
wind speed • The value depends on the operating mode and the equipment
configuration
Note:
If access to a load chart is not possible, then the maximum
value starts to blink and the acoustic alarm “Short
horn” sounds.
If the current wind speed value exceeds the displayed
maximum value, the maximum value starts to blink and the
acoustic alarm “short horn” sounds.
The crane movements will not be shut off!
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3 Icon “Support force • The LICCON support force monitoring system continuously
display” * records the current hydraulic pressure present in all 4 support
cylinders during crane operation using a pressure sensor and
converts this into a support force [t] value for each support.
The icon “Support force display” * 3 may be displayed in the
“Operation” program if required, or the icon appears
automatically with the alarm signal “short horn” when a critical
situation occurs, when a support has reached or exceeded
maximum force or has reached or fallen below the minimum
force. The corresponding value is shown by a blinking display.
Note:
The same maximum support force and a common minimum
support force is programmed for each support at the factory.
These 5 values may be changed in the “Support” program,
depending on the situation. (refer to section “Changing the
minimum and maximum support force monitoring”)
Independent of the programmed minimum / maximum values
monitoring is continuous, if the total of the two lowest support
forces is less than 15 % of the total support forces. If this limit is
fallen below, the two supports with the lowest forces are
shown.
DANGER
Danger!
When reaching the programmed minimum / maximum supporting forces, no automatic shut off of
the crane movements occurs!
DANGER
When the two supports with the lowest force are in the direction of the boom, telescoping in is
switched off.
3.1 Display of current support • Display of support force for each support
force
DANGER
Danger due to erroneous support force display!
The support force display may in some circumstances be defective or inaccurate.
Also refer to hazard warnings in section “Support / Comments”.
3.2 Weight unit of support • In [t] or [lbs]

force
3.3 Display of support base
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4 “Slewing range” icon

4.1 Maximum slewing speed • V: [%]
• Identifies the current (selected) “maximum slewing speed” of
the slewing gear with a fully deflected master switch, relating to
the maximum attainable slewing speed of the slewing gear at a
preselected speed of 100%.
This value may be selected in fixed percentage stages in the
LICCON program “Control Parameter”.
DANGER
Danger of accidents in case of excessive slewing speed!
Make the preselection according to the specifications in the load chart.
4.2 Current superstructure • In relation to the main working direction “to the rear” (0 [°])
position* Increases clockwise to a maximum value of 180 °
4.2.1 Direction of deviation The arrow in front of the value indicates the direction of the
deviation.
• Arrow to the right: Turn to the right
• Arrow to the left: Turn to the left
4.3 Status of lock between
superstructure and
chassis
4.3.1 Lock is static • Locking pin on top: Superstructure unpinned
4.3.2 Lock is blinking • Locking pin in intermediate position: Error
4.3.3 Lock is static • Locking pin down, ±5° toward the rear: Superstructure pinned
to the rear
4.3.4 Lock is blinking • Locking pin down, ±5° not toward the rear: Superstructure
pinned
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5 “Telescopeable • This icon is automatically shown if “telescoping” crane

load” icon movement has been selected and the telescopic boom is still
pinned.
The weight unit [t] or [lbs] defined in the load chart is displayed
in the icon, under which the selected telescopic section can still
be unpinned and then telescoped.
• The displayed value begins to flash and the acoustic alarm
“short horn” sounds, if the load on the hook is greater or if the
displayed value is “0”.
• If the telescopic boom is not pinned, the icon “Maximum
load” 1 shows the same value as the icon “Telescopeable
load” 5 and the icon “Telescopeable load” 5 no longer
appears automatically, but only after pressing the function
key F3.
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5.5 “Winch display” icon

1 “Winch2” icon • The meanings for the icons for winch1 and winch2* are the
same, and are explained at the icon “winch1” 2.
2 “Winch 1” icon
2.1 Travelled distance • In [m] or [ft]
From a zero point to be determined
• For single operation with the reeving setting made in the
“Configuration” program: completed hook path
for parallel operation: distance completed by hook block
• The positions before the decimal point are displayed with
a maximum of 3 large digits. The digits after the decimal point
are displayed with small digits. (Also refer to the description of
the function key F1 and function key F2.)
• A precondition for a correct display is that the value entered
equals the actual number of rope strands between the boom
head and the hook block.
If the set reeving does not correspond with the reeving of the
appropriate winch (for example, winch on the boom nose at a
set load chart for the main boom), the correct hook path can be
calculated from the displayed hook path as follows:
Legend:
• sHk = correct hook path
• sHa = displayed hook path
• ne = selected reeving
• nt = actual reeving
• The hook path calculation only works accurately if the load is
suspended freely and is not luffed during the lifting procedure.
Not taken into account are flexation and rope expansion.
• Note:
The length display (hook travel display) is only accurate and
the layer sheer is only taken into account correctly if the winch
has been calibrated and no interruptions of the CPU power
supply have occurred (cold start). The hook travel display is
calibrated by spooling the rope up or out until the calibration
switch reacts.
2.2 Direction of hook The arrows on the length value show the direction of the hook
movement movement in relation to the zero point:
• Arrow pointing up: Hook has moved upward from the zero
point.
• Arrow pointing down: Hook has moved down from the zero
point.
2.3 Length unit for hook path • In [m] or [ft]
display
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2.4 Winch status display • There are five winch status icons (all blinking):
2.4.1 spool out
2.4.2 spool up
2.4.3 Spooled out • Spooling out is blocked
2.4.4 Spooled up • Spooling up is blocked
2.4.5 Winch is deactivated or • Spooling up and spooling out are blocked (via “Control
unplugged parameter” program).
• Note:
If no winch status icon appears, the activated winch is inactive
and is neither spooled up nor spooled out.
2.5 Winch icon • (With rope end for winch status icon)
2.6 Winch number with • Example: 1 : 1 Y
master switch number First digit: Winch number
and master switch Second digit: Master switch number
operating direction Letter: Master switch operating direction
2.7 Vibration sensor* • If the vibration sensor is turned on for a winch on the master
switch, the vibration sensor* 2.7 icon appears in the winch
icon.
The vibration sensor is added at the first actuated crane
function.
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5.6 The function key line

The function key line consists of function keys F1 to F8 and the function key icon bar above it. The
function keys correspond to the various function key icons above them.
The function key icons may trigger a function or they change their appearance upon the push of a key
(function keys) and thereby their definition.
Not all function keys must have assigned icons. This depends on the “active” program selection.
Pressing a function key changes the appearance of the icon above, its meaning, or its textual content.
F1 Function key • Zero point for hook travel display winch2*
• Pressing the function key F1 causes the “Set winch display to
zero” icon to appear, i.e. the winch 2* hook path display in the
winch icon above is set to “000.00” when the key is pressed.
The path measurement begins here.
F2 Function key • Zero point for hook travel display winch 1
• Pressing the function key F2 causes the “Set winch display to
zero” icon to appear, i.e. the winch1 hook path display in the
winch icon above is set to “000.00” when the key is pressed.
The path measurement begins here.
F3 Function key • Turn monitoring icons on / off
• The function key F3 can be used to turn all the monitored
auxiliary functions in the crane on or off.
• The appearance of the icon changes according to the
condition:
• “thick border” = auxiliary function icons turned off
• “thin border” = auxiliary function icons turned on
• Note:
The monitoring system of all auxiliary functions is always
active; only the icons can be faded out. If a monitored limit has
been exceeded, an acoustical signal (horn) sounds and the
corresponding icon is displayed, even if the monitoring symbols
have been hidden.
F4 Function key • Change monitoring page (if present)
see also section “Monitored auxiliary functions”
F5 Function key • Not assigned
F6 Function key • Not assigned
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F7 Function key • Taring

• When the function key F7 is pressed, the actual load display is
set to “zero”. At the same time, the word “net” appears in the
icon of the actual load display. This function, for example,
makes it possible to eliminate the weights of the hoist rope,
load carriers, lifting and attachment equipment and only display
the weight of the load that must be lifted (net load).
If the taring is cancelled, the word “net” disappears from the
icon “Actual load display” and the gross load value is displayed.
• Taring is cancelled by one of the following three actions:
• By pressing the function key F7 again
• Telescoping the boom by more than 3 length units (dm or
1/10 ft.).
• By luffing by more than ± 4°
F8 Function key • Turn off horn / error diagnostics
• Turn off the acoustic warning
The “Horn” and “Short horn” acoustic warnings can be turned
off by pressing the function key F8.
A new error turns the acoustic warning on again.
• Error message in “Horn” icon
If a system, application or operating error occurs, an error
message appears in the “Horn” icon (refer to illustration 1).
Example: E:0EAM1
By pressing the function key F8 twice, the acoustic warning is
turned off and the “Test system” program switches to the error
determination screen where the error is documented. (see
Diagnostics)
• Special function “Horn” icon
A special program is available for crane acceptance in the
LICCON computer system. This program is blocked after
completion of crane acceptance. If an additional marking is
displayed in the “Horn” icon (talons along the upper margin,
see illustration 2), this means that the acceptance program is
not yet blocked. Contact LIEBHERR Service immediately.
In order to prevent error functions, access to the special
program is only permitted for trained LIEBHERR
personnel.
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5.7 Other operating elements

The following functions are assigned to the other operating elements of the display and operating unit
of the LICCON computer system in program “Crane operation”.
A Keypad • Keys “0” to “9” and “P” have no function in the “Crane
operation” program
• “SHIFT” and “.” keys
Using key “.”, the so-called test pattern function is turned on
and off, meaning that all available symbols appear on the
LICCON monitor with an incorrect display value.
Note:
The monitored auxiliary functions, however, must be opened
on the desired page if they are to appear in the test pattern.
The test pattern display may be held by pressing the
“SHIFT” key and “.”, otherwise the normal operating screen will
appear after 10 seconds or after pressing the key “.” again.
P Program keys • The program keys are used to select individual programs.
However, the appropriate program-specific features (for
example, switching from “Configuration” to “Crane
operation” using the “O.K.”) must always be observed.
Note:
A program currently running cannot be called again using its
program key.
The programs can only be called up with their program key
when the set up key was not actuated before.
C Enter key • No function in “Crane operation” program
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D Set up key • Position to right (touching):

Bypass hoist limit switch and exceed shut off of load moment
limiter (if shut off available)*
Note:
• Operating position (self-retaining):
Normal operation
• Exceed shut off limits of overload protection:
If the maximum permissible load moment is exceeded, the
LICCON overload protection turns off all crane movements that
increase the load moment. This shut off can be exceeded by
the configuration button D in the “right touching” position.
DANGER
Increased accident risk when exceeding the overload protection!
If the overload protection is exceeded, there is no additional protection against crane overload!
All LICCON overload protection displays remain functional.
In the event of deliberate improper use, the crane could collapse, the boom can break off or the crane
can topple over!
Personnel can be killed!
This could result in high property damage!
It is only permitted to exceed the overload protection for assembly purposes or in emergencies!
The configuration button D may only be actuated by persons who know the effects of exceedance!
Exceeded the overload protection may only be done if the crane supervisor is present and with
utmost caution.
Crane operation with overload protection exceeded is prohibited!
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• Bypass of the hoist top shut off

If the hook block touches the hoist limit switch weight during
the upward movement, the hoist limit switch reacts. The crane
movements “Spool up winches”, “Luff telescopic boom
down” and “Telescope out” are shut off. This shut off can be
bypassed by the configuration button D in the “right
touching” position, at a reduced working speed* (forced neutral
position).
DANGER
Increased accident risk when bypassing the overload protection!
When bypassing the hoist top shut off, there is a risk that the hook block may be pulled against the
pulley head when continuing to lift or luffing down the boom. This may damage the pulleys and cause
the loads to fall!
The hoist up shut-off must only be bypassed if the crane supervisor is present, and with the help
of a “guide”. The guide must be in direct contact with the crane operator and must continually
monitor the distance between the hook block and the boom head!
Carry out all crane movements with maximum care and minimum speed!
E Special function keys • Monitor brightness adjustment (see section “Control elements
of the LICCON computer system”)
H “SHIFT” key • Second level key assignments
“SHIFT” and “P0”: Program call up for Engine monitoring
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6 “Telescoping” program
The telescoping screen shows the crane operator the pinned state of the telescopic boom, the
position of the individual telescopes and the extension state of the telescoping cylinder, in full dynamic
graphics (refer to chapter 4.05 “Crane operation”).
6.1 Starting the program

Press program key P4.
or
Automatic start from “Operation” program when telescoping target (A!) 9.1 is reached and
telescoping at master switch.
6.2 User interface

For a description of icons 2 to 7, see section “Alarm functions” in the “Operation” program.
2 Preventing further • Based on exceeding the expected load in the unpinned state
telescoping processes in • Note:
relation to the telescoping This is the same program-specific illustration of the same topic
cylinder as in section “Telescopeable load”.
3 Icon “Hoist top” icon at
HES1 and / or HES2
4 “Hoist top” icon on HES3
or HES4
6 “STOP” icon
7 “Radius” icon
7.1 Radius • In [m] or [ft]
7.2 Main boom angle to the • In [°]
horizontal
8 “Stylized illustration of the
telescopic boom” icon
8.1 Current extension • In [%]
condition of telescopes 1
-5
8.2 Current extension • In [%]
condition of telescoping
cylinder
8.3 Display of actual load and • In [t] or [lbs] and in [%]
utilization of crane in
percentages
8.4 Engine RPM • In [rpm]
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9 “Automatic telescoping
mode” icon
9.1 preselected telescoping
target reached
9.2 Nominal deflection Request:
direction of master • Telescope in = down arrow
switch • Telescope out = arrow up
9.3 Error in system
10 “Selected telescoping
targets of telescopes 1
-5” icon
10.1 Target selection for
telescopes 1 -5
10.2 Blinking marker (arrow) • To the selected telescoping target
• As a warning in the event of incorrect operation, target already
reached, or enter new target.
11 Function key line
F1 Function key • Switch between automatic operation and manual telescoping
F3 Function key • Target selection Telescope 1
F8 Function key • Press once:
Turn the acoustic signal off
• Press twice:
Errors shown in the “Horn” icon are automatically displayed in
the error determination screen (see chapter “Diagnostics”).
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7 “Control parameter” program

The “Control parameter” program offers the following possibilities:
– Preselection of maximum slewing gear rotation speed
– Preselection of the maximum winch rotation speed and activation / deactivation of winch 1 and
winch 2*
– Preselection of the telescopic boom maximum luffing speed
During the “control parameter” program the set up key D is monitored. If the set up key D is operated
during the program, then the program is immediately switched back to the “Operation” program.
DANGER
Risk of accident!
Never change the maximum speeds or the activation / de-activation of the winches during a crane
movement.

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7.2 User interface

1 Crane type
2 Selector • Double arrow pointing down
• For selecting icons
3 “Slewing gear” icon
3.1 “Maximum slewing • Vmax in [%]
speed” icon
4 “Winch” icon group
4.1 Winch 1
4.2 Winch 2*
4.4 Selector • Arrow to the right
• For selecting winches
4.5 Winch icon
4.5.1 Winch activated
4.5.2 Winch deactivated
4.6 Speed • In [%]
• See value field with selector
5 “Maximum luffing • Vmax in [%]
speed” icon
6 Value field with selector • The percentage values relate to the speed with maximum
deflection of the manual control lever, always in relation to the
maximum achievable speed of the drive, with 100%
preselected speed. Five stages may be preselected.
7 Function key line
F4 Function key • Winch selection
F5 Function key • Activation and deactivation of selected winches
F7 Function key • Selection of percentage value for respective speed in value
field
F8 Function key • Switch back to “Operation” program and accept parameters
8 Input key “ENTER” • Accept selected speed setting to the preset functions
9 Special function keys
E1 Special function key • Moves the selector 2 for selecting icons to the left
E2 Special function key • Moves the selector 2 for selecting icons to the right
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7.3 Changing the maximum rotation speed of slewing gear

DANGER
Risk of accident!
Always adhere to the maximum speeds relative to the boom length and the operating modes
during crane operations with loads (according to load charts)!
The greater the boom length, the heavier the equipment and the greater the load, the smaller the
set “maximum rotation speed”.
Never deflect the master switch for the slewing gear to the stop at maximum load.
Using the special function key E1 or special function key E2, select the icon “maximum rotation
speed” 3.1.
Result:
– Selector (double arrow down) 2 appears above the icon.
Select the maximum rotation speed in [%] with function key F7.
Result:
– Selector (arrow to right) 6.1 shows the selected percentage value.
Use the “Enter” key 8 to confirm the selected maximum rotation speed.
Result:
– The value of the maximum rotation speed will be accepted.
7.4 Winches
7.4.1 Changing maximum rotation speed

Using the special function key E1 or special function key E2, select the icon group winches 4.
Result:
– Selector (double arrow down) 2 appears above the icon group.
Using the function key F4, select the icon for winch 1 or winch 2*.
Result:
– Selector (arrow to right) 4.4 shows the selected winch.
Select the maximum rotation speed in [%] with function key F7.
Result:
Use the “Enter” key 8 to confirm the selected maximum rotation speed.
Result:
– The value of the maximum rotation speed will be accepted.
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7.4.2 Activating / deactivating individual winches

In order to prevent unintentional activation of a winch that is currently not required, de-activate
individual winches.
Using the special function key E1 or special function key E2, select the icon group winches 4.
Result:
– Selector (double arrow down) 2 appears above the icon group.
Using the function key F4, select the icon for winch 1 or winch 2*.
Result:
– Selector (arrow to right) 4.4 shows the selected winch.
Using the function key F5, activate or deactivate the selected winch.
Result: The winch icon in the icon changes the appearance:
– Winch icon crossed out = winch deactivated 4.5.2
– Winch icon not crossed out = winch activated 4.5.1
7.5 Changing maximum luffing speed

Using the special function key E1 or special function key E2, select the “maximum luffing
speed” icon 5.
Result:
– Selector (double arrow down) 2 appears above the icon.
Select the maximum luffing speed in [%] with function key F7.
Result:
Use the “Enter” key 8 to confirm the selected maximum luffing speed.
Result:
– The value of the maximum luffing speed will be accepted.
7.6 Switching back to the “Operation” program

Press function key F8.
Result:
– The parameters previously confirmed using the “Enter” key 8 will be accepted.
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8 The “Working range limitation” program*

A detailed description of operating range limitation can be found in the separate operating instructions
for “Working range limitation”.

8.2 User interface

1 “Pulley head height
limitation” icon
2 “Radius limitation” icon
3 “Slewing limit stop” icon
3.1 Right slewing limit stop
3.2 Left slewing limit stop
4 “Edge limit with edge and • The limit function icons are shown crossed out if they are
point selection” icon inactive.
5 Function selector • For selecting limiting functions
6 “Graphical display of
programmed limits” icon
7 Function key line
F1 Function key • Select point 1 or 2 of selected edge A or B
F2 Function key • Selection of edge A or B that is being programmed
F3 Function key • The function selector is moved down by one limit function
F4 Function key • The limit function selected with the function selector changes
its status. If previously active, it will now be inactive when the
function key F4 is pressed, and vice versa. An inactive limit
function is identified by a crossed out icon. If the function
selector shows a slewing limit to the left or the right, then both
limits will always be switched.
Note:
For the edge limit, only the preselected edge will be switched.
The edge that is not displayed can be active or inactive at the
same time.
F5 Function key • All limit functions become inactive
F8 Function key • Exit the program and return to the “Operation” program
8.3 Displays in “Operation” program

If a programmed operating range limiter is activated, this condition is indicated in the
“Operation” program by an alternative STOP icon in the position of the normal LMB STOP icon (see
section “Alarm functions” in “Operation” program).
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9 The “Support” program

The “Support” program can contain up to three separate and independent parts (customer request).
The monitor screen shows the complete configuration of the “Support” program. Depending on the
customer request, the individual parts of the program are inactive and therefore not visible on the
LICCON monitor. The numerical values in the icons are only examples and may differ from the crane.
9.1 Starting / stopping the program
9.1.1 Starting the program

9.1.2 Stopping the program

Result:
– Program is ended.
– System switches back to the “Operation” program.
9.1.3 Program configuration

Supporting
• Manual supportting
• Automatic supporting and aligning the crane in horizontal direction
• Crane operation in “Support” program
Support force monitoring *
This support force monitoring records the current pressure continuously during operations on all four
support cylinders using pressure sensors, and displays this as the supporting force for every support.
Because the limit values are variable and programmable, the support force monitoring can also be
used for advance warning.
Sliding beam length display *
The sliding beam length display shows the extension state of the individual sliding beams in [%].
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9.1.4 Supporting
Manual supportting
A detailed description may be found in chapter 3.05 “Crane at work site”.
4 Monitoring and control
field
4.1 Crane icon
4.2 Support base • [m] or [ft]
4.3 Function selectors • For selecting the support cylinders
4.4 Function selectors • For selecting the sliding beams
Function key line in monitoring / control mode (during program start)
F2 Function key • Sliding beam illumination, turn on / off manually
F3 Function key • Extend preselected support cylinder(s)
F4 Function key • Retract preselected support cylinder(s)
F5 Function key • Extend preselected sliding beam
F6 Function key • Retract preselected sliding beam
F7 Function key • Select the sliding beam
F8 Function key • Press 1x = to turn the acoustical signal off.
• Press twice = fields that are displayed visually in the
“Horn” icon are automatically displayed in the error
determination display. See also chapter 7.10 “Diagnostics”.
Note
Note
Only one sliding beam may be selected for safety reasons.
Pressing the function keys “F3” and “F4” is only meaningful if a sliding beam has also been
pre-selected. A horn sounds if no support cylinder has been selected.
For safety reasons, the functions of the function keys “F3” to “F6” are only active as long as the
appropriate key is pressed.
A “rhythmic beeping sound” sounds for the duration of the function as acoustic feedback.
6 Keypad • The relevant support is selected or deselected using keys 1 to

4.
21 “Incline” icon • See monitored auxiliary functions, “Incline” icon.
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Automatic supporting and aligning the crane in horizontal direction
“SHIFT” + “F3” • By pressing the key combination “SHIFT” + “F3”, all support
cylinders are extended and the crane is horizontally aligned.
“SHIFT” + “F4” • By pressing key combination “SHIFT” + “F4”, all support
cylinders are retracted and the crane is horizontally aligned.
Note
Note
By taking the incline values provided by the level control sensor into account, the supports are
moved as long as the key is pressed, independent of the preselected direction, so that the crane is
levelled.
DANGER
Risk of accident!
You must check that all four support plates are in contact with the ground. If this is not the case,
an accident hazard exists.
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Crane operation in “Support” program

This function is only enabled for the “Support force monitoring” option*.
For a description of the icons, see section “Alarm functions” in the “Operation” program.
10 “Boom radius and main
boom angle” icon
10.1 Load projection radius on • In [m] or [ft]
the boom
10.2 Boom angle • In [°]
11 “STOP” icon
13 “Hoist top” icon • At HES3 or HES4
14 “Hoist top” icon • On HES1 and / or HES2
20 “Load” icon
20.1 Maximum load on the • In [t] or [lbs]
boom
20.2 Current load on the • In [t] or [lbs]
boom
20.3 Dynamic utilization • In [%]
21 “Incline” icon
21.1 Graphic part
21.2 Numeric part
21.2.1 Incline range • 1° or 5°
21.2.2 Incline • Of crane in lateral direction
21.2.3 Incline • Of crane in longitudinal direction
Function key line:
F1 Function key • Switching over into the adjustment field for support limit forces
(refer to section “Support force monitoring”)
• Note:
In that event, an LMB-STOP will be immediately triggered. All
hoist and luffing moments are stopped and the icons for crane
operation disappear.
F8 Function key • End adjustment mode
All crane operations icons reappear and all crane movements
are enabled again.
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9.2 Support force monitoring*

DANGER
Risk of accident!
The LICCON supporting force monitoring is only an aid. It does not prevent a possible crane
overload.
Never use Support force monitoring in order to use the crane up to its tipping limit.

field
4.1 Crane icon with support
numbers
4.2 Support base • In [m] or [ft]
4.5 Support force values • In [t] or [kips]
4.6 Unit of displayed support • In [t] or [kips]
forces
Function key line in monitoring / control mode:
F1 Function key • Switch to the adjustment field for support limit forces
• Press twice:
Any errors shown in the “Horn” icon are automatically displayed
on the error determination screen (see chapter “Diagnostics”)
5 Adjustment field for
support force limits
5.1 Unit of maximum support • In [t] or [kips]
force limit values
numbers
5.3 Maximum support force • Max in [t] or [kips]
limit values
5.4 Minimum support force • Min in [t] or [kips]
limit value Valid for all four supports
5.5 Selector arrows • Point to the active settings field
Function key line in adjustment mode:
F1 Function key • Move cursor (input pointer) to next support force limit value
F2 Function key • Move cursor (input pointer) to previous support force limit value
F8 Function key • Switch back to the Monitoring and control field 4
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9.2.1 Display current support forces

Display current support forces in operating screen, see “Monitored additional function for crane
operation”.
9.2.2 Remarks
Because of the option to determine limit values yourself, the LICCON supporting force monitoring can
also be used as a way of giving advance warning.
Bear in mind however that the screen display may be inaccurate. Because of friction in the support
cylinders, depending on the type of machine, a measurement error of up to ± 2 % of the maximum
load carrying capacity of a crane is possible.
This applies particularly:
– In case of large support forces
– In case of far extended support cylinders
– When extending the support cylinders (up to 15 minutes afterwards)
In order to ensure that the LICCON supporting force monitoring system operates correctly with an
accurate display, do not let the support cylinders move either to “the block below” or “the block
above”.
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9.2.3 Modifying minimum and maximum support force limits

As an additional safety precaution, this program monitors the set up key. If assembly operations are
attempted, the system switches back to the “Operation” program.
In the Monitoring and control field 4 the current support force values are displayed.
If one or more of the values are below or above the programmed maximum values for the support
force limits, then they are displayed blinking.
The programmed maximum / minimum values for the support force limits are displayed in the
adjustment field 5.
Ensure that:
– The crane is supported during operation.
– The set up key is not pressed.
The program initially runs in monitoring mode. All icons relevant to crane operation are displayed.
Note
Switching to the adjustment field for support limit forces.
An LMB-STOP will be immediately triggered. All hoist and luffing moments are stopped and the
icons for crane operation disappear.
When pressing the function key F1, the two double arrows 5.5 point to the settings field 5 for support
limit forces. The cursor appears on the maximum value of the support limit force on support 1.
On operating the function key F1 or function key F2 you switch the cursor to the next or previous
maximum value for the support limit force, or the minimum value for the support limit force (valid for all
four support of cylinders).
Note
Testing the validity range for the support limit force values.
Every newly entered support limit force value will be tested for its validity range.
If valid, the value entered will be accepted.
If invalid, the value will be rejected as too small or too big with an “Error” message.
Using the alphanumeric keys, you can change the support limit force values and then close the input
function using the Enter key.
Use the function key F8 to switch back to the Monitoring and control field 4.
Use the program key P1 to switch back to the “Operation” program.
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9.3 Sliding beam length display*

field
numbers
4.2 Support base • In [m] or [ft]
4.7 Sliding beam length • In percent of the maximum extension length
values • The sliding beam length values blink in the ranges that are
unsuitable for supporting.
4.8 Percentage sign • Unit for sliding beam length display
Function key line when program starts (monitoring / control):
• Press twice:
Any errors shown in the “Horn” icon are automatically displayed
on the error determination screen (see chapter “Diagnostics”)
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10 The “Engine monitoring” program

All engine-related data is displayed by the “Engine monitoring” program, such as the engine oil
pressure, coolant temperature etc. Switching over from the programs “Operation”, “Support” or
“Telescoping” is automatic in case of a problem.
If the chassis motor is turned off during the crane operation, only data for the crane engine is
displayed in the event of a failure or when switching to the engine monitoring screen.

The program starts automatically:
Once if a STOP event takes place during crane operations (at least one master switch is deflected
or activated). The engine monitoring screen is displayed for 3 seconds and then automatically
reverts to the operating screen.
or
At an advance warning, warning or STOP event during the start-up of the LICCON computer
system.
This is how you start the program on request:
In that case the engine monitoring screen is retained, and all load torque increasing crane
movements are locked or turned off.
Press of the key combination SHIFT and P0 (Configuration).
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10.2 Possible engine monitoring advance warning, warning and STOP

events
Events Advance Warning 5.2 STOP 6.2

warning
Engine oil pressure (display value) missing x
Erroneous engine oil pressure (display value) x
Engine oil pressure warning active x
Coolant / charge air temperature (display value) missing x
Erroneous coolant / charge air temperature (display x
value)
Coolant / charge air temperature warning active x
Coolant level warning active x
Hydraulic oil temperature (display value) missing x
Erroneous hydraulic oil temperature (display value) x
Hydraulic oil temperature (display value) too high x
Air filter monitoring x
Battery voltage (display value) missing x
Erroneous battery voltage (display value) x
Battery voltage not between 16 V and 36 V x
Fuel reserve (display value) missing x
Erroneous fuel reserve (display value) x
Fuel reserve (display value) 10 % or less x
Fuel reserve (display value) 6 % or less x
Fuel reserve (display value) 1% x
If the system automatically switches to the “Engine monitoring” program when an engine STOP event
occurs, there is an option for retaining the engine monitoring screen within 3 seconds (retaining the
engine monitoring screen is achieved by pressing the function key F1). Switch back to the operating
screen using the function key F8 (OK) or the program key P1 (Operation). If the engine monitoring
screen is not retained, then after 3 seconds the system switches back automatically to the
“Operation” program.
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10.3 Retaining the engine monitoring screen

The automatic change over to the engine monitoring screen can only take place from the “Operation”,
“Telescoping” or “Support” programs.
If you confirm a monitoring event in the engine monitoring screen with the function key F8, then there
will be no automatic change over to the engine monitoring screen for the same event.
On switching back to the “Operation” program, the STOP icon 6.2 or the Advance warning
icon 5.2 appears. There is no indication about advance warnings in the “Operation”, “Telescoping” or
“Support” programs.
WARNING
There is a danger of severe damage to the engine if STOP events are ignored!
If other programs are used for extended periods of time, for example the “Configuration” or “Test
system”, it is essential to switch occasionally to the engine monitoring screen in order to ensure that
no engine monitoring events have occurred, which could lead to damage or destruction of the engine.
Switch over occasionally to the engine monitoring screen!

Result:
– Icon frames are displayed with a thin border.
– All load moment increasing crane movements will be turned off or blocked.

Result:
– System switches back to the “Operation” program.
– The block of the load moment increasing crane movements will be lifted.
– The warning or STOP icons are faded into the “Operation” program.
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10.4 Engine monitoring icons
10.4.1 Crane engine

10 Tank contents • In [%]
Icon blinks the fuel reserve is less than 10%.
11 Oil pressure • In [bar]
Numeric display in icon blinks if the engine oil pressure is too
low.
12 Coolant / charge air • In [°C]
temperature
12.1 Coolant temperature • Numeric display blinks if the coolant temperature is too high.
12.2 Charge air temperature • Numeric display blinks if the charge air temperature is too high.
13 Coolant level too low • Icon appears if the coolant level is too low.
14 Air filter is dirty • Icon appears if air filter is dirty.
18 Auxiliary function - • In [V]
Battery voltage Numeric display in icon blinks if the operating voltage is less
than 16 volts or above 36 volts.
10.4.2 Engine / Travel motor

20 Tank contents • In [%]
Icon blinks the fuel reserve is less than 10%.
21 Oil pressure • In [bar]
Numeric display in icon blinks if the engine oil pressure is too
low.
22 Coolant / charge air • In [°C]
temperature
22.1 Coolant temperature • Numeric display blinks if the coolant temperature is too high.
22.2 Charge air temperature • Numeric display blinks if the charge air temperature is too high.
23 Coolant level too low • Icon appears if coolant level is too low.
24 Air filter is dirty • Icon appears if air filter is dirty.
26 Icon “Transmission • Blinks:
problem” Problem in automatic transmission
• Static:
Overloaded clutch or loss of air pressure
28 Auxiliary function - • In [V]
Battery voltage Numeric display in icon blinks if the operating voltage is less
than 16 volts or above 36 volts.
10.5 Function key line

F1 Function key • Retaining the engine monitoring screen
F8 Function key • Switching back to the “Operation” program
The function keys F2 - F7 are not used.
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11 LICCON computer system in stand-by mode
11.1 Starting LICCON computer system in stand-by mode

There are two ways of achieving stand-by mode with the LICCON computer system:
– Starting the LICCON computer system without engine
– Turning off the engine with the engine stop key
Starting the LICCON computer system without engine:

Turn the ignition key 320 to position “I” and leave it there.
Result:
– The LICCON computer system runs and the monitor shows the configuration screen, or
alternatively for a stop / warning / advance warning, the engine monitoring screen.
Press function key F8 (O.K.).

Result:
– System switches to the “Operation” program.
Turning off the engine with the engine stop key:

Actuate the switch 433.
Leave the ignition key 320 in position “I”.
Result:
– The engine is turned off.
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11.2 Active stand-by operation / alarm

The operating programs and the monitor displays function exactly the same as in the turn-on
procedure for the LICCON computer system with engine start (crane operation).
No crane movements are possible. If a crane movement is selected anyway, a message appears
on the LICCON monitor.
Example: Control turning shut off, the crane engine is not running.
The duration of the stand-by operation is 15 minutes, of which 3 minutes are the stand-by alarm.
Operating the LICCON computer system during Stand-by operation automatically extends the
stand-by time.
In stand-by operation no keys are pressed on the monitor.
Result:
– The stand-by alarm (horn) is reached after 12 minutes.
– This screen appears on the monitor: STANDBY (see illustration).
Now press any key on the LICCON monitor.

Result:
– System switches back to the interrupted program.
– The stand-by time is extended by a further 15 minutes.
During the stand-by alarm (Duration: 3 minutes) no keys on the monitor are pressed.
Result:
– The LICCON computer system shuts completely off. The shut off is announced by acoustical
signals 60 seconds in advance (short horn) and 30 seconds in advance (long horn). The power
supply of the LICCON computer system turns off.
– This screen appears on the LICCON monitor: CRT self test: ERROR: Host Interface:
Break! (Refer to the illustration) and the indicator light 315 and the indicator light 316 blink. In this
case, this is not an error message from the LICCON computer system, the error message appears
only on the monitor because the connection between the monitor and the CPU is broken.
11.3 Start prevention

Starting the engine again after complete shut down of the LICCON computer system:
Return the ignition switch 320 first to position “0”.
Turn the ignition switch 320 to position “I” (note the preheating time).
Turn the ignition switch 320 briefly to position “II”.
Result:
– The engine starts.
4.02 LIEBHERR 415

026705-00 4.03 Crane start up and taking the crane out of service
B198140
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4.03 Crane start up and taking the crane out of service 026705-00
1 Checks before starting up

Various checks must be performed before starting up.
1.1 Checking oil level and filters

Check engine oil level.
Check oil level in hydraulic fluid reservoir.
Check filter on hydraulic fluid reservoir.
1.2 Checking the fuel level

Note
Deaerate fuel system.
If the fuel tank has been run dry, always deaerate the whole fuel system.
Do not run the fuel tank dry.
On the LICCON monitor, the amount in the tank is given in the form of a numerical display in percent
[%].
Check tank contents on LICCON monitor.
1.3 Checking the coolant level

WARNING
Danger of injury due to scalding of the skin.
Engine must be cold when performing coolant level check.
Fill coolant expansion tank up to overflow on filler neck.

Check the coolant level.
1.4 Checking central lubrication system

The grease container must be kept filled with grease as specified in the lubrication chart, see chapter
7.05.
Check the grease container.
4.03 LIEBHERR 417

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1.5 Checking general condition of crane

DANGER
Risk of accident from falling parts!
Before raising the boom, check that there are no loose parts on the main boom and/or the
auxiliary boom, such as pins, safety springs or ice.
Check that the crane is properly supported on a level load-bearing surface, and has been set up
horizontally.
Check that the toothed ring of the slewing ring connection is clean and greased.
Check the air supply to the oil cooler and water cooler.
Check that the side covers are closed and locked.
Ensure that there are no people or objects in the crane danger zone.
Make sure that the cable / rope drums and the limit switches are free of snow and ice.
Make sure that there are no loose parts on the superstructure or the telescopic boom.
4.03 LIEBHERR 419

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2 Crane operator's cab workplace
2.1 Adjusting crane operator's seat

The crane operator's seat can be adjusted to suit different body sizes.
Using the lever 302, adjust angle of seat.
Using the lever 302, adjust height of seat.
Using the button 303, adjust pneumatic lumbar support in lower part of backrest.
Using the button 304, adjust pneumatic lumbar support in upper part of backrest.
Using the manually operated lever 305 unlock the horizontal seat adjustment.
Using the lever 306, adjust the inclination of backrest.
Use the clamping screw 323 to adjust the control station in longitudinal direction.
Using set screw 325, adjust angle of arm rests.
Using the lever 326, adjust height of the arm rests.
4.03 LIEBHERR 421

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2.2 Footboard
In order to make it easier for the crane operator to enter and leave the crane, the crane cab footboard
can be extended or retracted.
When you have finished working with the crane, retract the footboard again and secure it in the end
position.
2.2.1 Extending footboard

Swivel left arm rest upwards.
Pull lock 313 and operate switch 346 on top.
Result:
– Footboard is extended.
Release locking 313 as soon as the footboard extends.

Extend the footboard until it again locks into place.
2.2.2 Retracting footboard

Swivel left arm rest upwards.
Pull lock 313 and operate switch 346 on bottom.
Result:
– Footboard is retracted.
Release locking 313 as soon as the footboard retracts.

Retract the footboard until it again locks into place.
2.3 Turning the seat heating* on

Press switch 324.
2.4 Turning heater / ventilation on

The cab can be heated or ventilated to the desired temperature. The operating controls for heater /
ventilation are below the crane operator's seat. For a detailed description see Chapter 6.01.
2.4.1 Heating
Move variable switch 308 to recirculated air.
Turn the fan on using the rotary switch 309.
Control temperature with the variable switch 310.
2.4.2 Ventilation
Move variable switch 308 to fresh air.
Turn the fan on using the rotary switch 309.
4.03 LIEBHERR 423

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2.5 Tilting crane cab

To give the crane operator a better field of view, the cab can be tilted upwards.
When the cab is tilted, the cab doors will open more quickly and hit the backstop. Therefore hold the
door by the handle and open slowly.
When you have finished working with the crane, set it to horizontal.
CAUTION
Risk of accident!
If the cab is tilted, it is forbidden to stand on the footboard.
If the cab is tilted and the counterweight has been lowered on to the chassis, do not turn the
superstructure towards the rear.
2.5.1 Tilting cab upwards

Press bottom button 410.
Result:
– The cab swivels upwards.
2.5.2 Moving the cab to a horizontal position

Press top button 410.
Result:
– Cab swivels downwards.
4.03 LIEBHERR 425

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2.6 Operating the windshield wiper / windshield washing system
2.6.1 Operating the windshield wiper

The windshield wipers for the windshield and the roof window are operated using a 2-stage switch
(first stage - intermittent, second stage - continuous wipe).
To activate the windshield wiper on the front window:
Press switch 366.
or
To activate the windshield wiper on the roof window:
Press switch 368.
2.6.2 Operating the windshield washing system

The windshield wipers on the front and roof windows can be assisted by a windshield washing
system.
Before the start of the cold season, fill the container for the windshield washing fluid with standard
antifreeze mix.
To activate the windshield washing system on the front window:
Press button 365.
or
To activate the windshield washing system on the roof window:
Press button 367.
2.7 Opening front window

WARNING
Danger of hand injury from trapping!
Be careful with your hands when closing the front window.
A pair of nitrogen gas cylinders provide help to lift the front window.
To open from inside, just press on the front window.
or
If you only want to partly open the window:
Use the attached strap to set the desired opening angle.
2.8 Checking the signal horn

Note
Use of signal horn!
Only use the signal horn in dangerous situations, to maintain its warning effect.
Before starting work, check that the signal horn is functioning.
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3 Starting and stopping superstructure engine and

chassis engine
The engine is only at full capacity when the operating temperature has been reached.
– the battery master switches are on
– the transmission is in neutral position “N”
– the rotary switch 34 is set to superstructure operation
3.1 Starting superstructure engine

Turn ignition switch 320 to position “I”.
Result:
– The control light 316 flashes.
– The control light 315 is lit.
The engine is ready to start.
CAUTION
Danger of equipment damage!
Only start the engine if the control light 315 is on, and the control light 316 is flashing.
Turn ignition switch 320 to position “II”.

Start the engine.
Troubleshooting
The engine does not start after a maximum of 10 seconds:
Wait for 1 minute. The starter can be operated three times for 10 seconds per attempt with a
pause in between of one minute each time.
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3.2 Starting the superstructure engine with heat flange control

The engine is equipped with a heat flange to improve the cold start process. The heat flange system
switches on at a coolant temperature below 10 °C. The heat flange controls are also activated
automatically at a coolant temperature above 25 °C and a charge air temperature of below -10 °C.
This switching-on setup is required for a hot engine and very cold air.
When the engine is started with heat flange controls, the idling speed will be automatically increased
to assist the battery.
WARNING
Battery functioning capacity in the cold season.
The starting capacity of the battery is considerably reduced in cold weather: for example, at a
temperature of -10 °C, the battery is at only 66% of its normal capacity

Result:
– The control light 316 lights up and then after a short time starts to flash.

Start the engine.
Troubleshooting
Is the control light 316 flashing rapidly?
The control unit has identified a defect with the heat flange system.
Rectify the defect.
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3.3 Starting chassis engine

Result:
– The control light 318 flashes.
– The control light 317 is lit.
CAUTION
Only start the engine if the loading control light 317 is on, and the control light 318 is flashing.

Start the engine.
Troubleshooting
The engine does not start after a maximum of 10 seconds:
Wait for 1 minute. The starter can be operated three times for 10 seconds per attempt with a
pause in between of one minute each time.
3.4 Starting chassis engine with flame starting device

To improve the cold start process and the warm-up phase, the engine is equipped with a flame
starting device.
The flame starting device switches off automatically if:
– The engine is not start when it is ready.
– The engine is started while the control light 318 is illuminated.
– The coolant temperature reaches 20 °C while the engine is running.
WARNING
Battery functioning capacity in the cold season.
The starting capacity of the battery is considerably reduced in cold weather: for example, at a
temperature of -10 °C, the battery is at only 66% of its normal capacity

Result:
– The control light 318 lights up and then after a short time starts to flash.

Start the engine.
Troubleshooting
The control light 318 flashes?
The control unit has identified a defect with the flame starting device.
Rectify the defect.
4.03 LIEBHERR 433

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3.5 Checking the instruments after starting the engine

As soon as a stable voltage is present with the engine running, the crane controls and the LICCON
computer system are automatically switched on. A self-test of the microprocessor system follows, and
after a few seconds the configuration state screen appears on the monitor.
3.5.1 Checking the instruments on LICCON monitor

The following icons must go off when the crane and driving engines are running:
Check the control light 315.
Check the control light 317.
Check the icon 11 and/or the icon 21 for the “engine oil pressure” on the LICCON monitor.
Troubleshooting
The number display for the engine oil pressure in the icon 11 and/or in icon 21 “engine oil
pressure” still flashes after about 10 s or begins to flash during the crane operation?
Engine oil pressure is too low. The engine could be damaged as a result of insufficient oil pressure.
Turn off engine and determine the cause.
Check the numerical display of the coolant temperature in icon 12.1 and icon 22.1.
Troubleshooting
The number display for the “coolant temperature” in the icon 12.1 and/or in the icon 22.1 is flashing
during the operation?
Coolant temperature is too high. Excessive coolant temperatures can lead to engine damage.
Turn off the engine immediately.
Check icon 10 or icon 20 for “tank contents”.

Check icon 19 for “hydraulic fluid temperature”.
Check icon 12.2 and/or icon 22.2 for the “charge air temperature”.
Check icon 13 or icon element 23 for “coolant level”.
Check icon 14 or icon 24 for “air filter”.
Check icon 26 for “gear box”.
Check icon 18 or icon 28 for “battery voltage”.
3.6 Engine monitoring

Refer to chapter 4.02, section Engine monitoring.
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3.7 Turning the superstructure engine off
3.7.1 Turning the superstructure engine off

If the crane has been operated at full engine output, or with very high coolant temperatures (above 95
°C), let the engine run without load for 1-2 minutes at idling speed.
Turn ignition starter switch 320 back to the stop.
Pull out ignition starter switch 320 and store in a safe place.
3.7.2 Turning the superstructure engine off in the event of danger
CAUTION
Operating the emergency-off switch
Only use the emergency off-switch 390 or the emergency off-switch 362 in case of serious
emergency. Use of the emergency off-switch 390 or the emergency off-switch 362 in normal
situations is forbidden!
Press the emergency-off switch 390.

or
Press the emergency-off switch 362.
Result:
– The crane will be turned off immediately.
3.8 Turning the chassis engine off

If the crane has been operated at full engine output, or with very high coolant temperatures (above 95
°C), let the engine run without load for 1-2 minutes at idling speed.
Turn ignition starter switch 319 back to the stop.
Pull out ignition starter switch 319 and store in a safe place.
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4 LICCON computer system after engine start

The LICCON computer system is only operational with the engine running.
4.1 Waiting for the run-up phase

After being switched on, the LICCON computer system runs up and carries out a self-test, see
chapter 4.02.
Wait for the run-up phase.
Result:
– The configuration screen appears on the LICCON monitor.
Normally, the most recently set configuration state and reeving number will be displayed.
If a master switch is moved away from the zero position during the run-up phase, the function circuit of
the electrical safety chain is interrupted.
In this case:
Turn off the engine and ignition and start again.
Troubleshooting
If an error message appears on the LICCON monitor?
Turn off the engine and ignition and start again.
The LICCON computer system automatically displays the troubleshooting display.
Troubleshooting
The LICCON monitor does not show the most recently set configuration state and reeving number?
If there has been a loss of data in the storage device (cold start), the first valid configuration state
appears in the configuration screen. The reeving number is set to “0”.
Set the configuration state and reeving number again.
4.2 Taking over the previously selected configuration and hoist rope
reeving
Check whether the correct short code and the correct reeving number have been selected on the
operating screen.
If the settings on the operating screen are correct:
Press function key “F8” 8.
Result:
– The “Configuration” program will terminate, and the parameters set will be accepted by the newly
started “Operation” program.
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4.3 Selecting the new configuration and hoist rope reeving

The selected and displayed configuration can be modified either by using the function keys or entering
the short code.
4.3.1 Selecting the new configuration using function keys

Press function key “F2” 2 until the desired main geometry status is selected.
Press function key “F3” 3 until the desired accessory status is selected.
Press function key “F4” 4 until the desired counterweight is selected.
Press function key “F5” 5 until the desired support base is selected.
Press function key “F6” 6 until the desired slewing area of the crane superstructure is selected.
Press key “ENTER” 9.
Check the set load chart.
4.3.2 Selecting new configuration with short code

The short code can be found in the load chart.
Entering the 4-digit short code with keypad A.
Press “ENTER” 9 key.
Result:
– The data of the selected load chart can be viewed.
For a more detailed description of the “Configuration” program, see chapter 4.02.
Check the set load chart.
4.3.3 Selecting the new hoist rope reeving

Press function key “F7” 7 until the desired reeving number is selected.
or
Press function keys “SHIFT” 10 and “F7” 7 until the desired reeving number is selected.
4.3.4 Checking the new configuration and hoist rope reeving and accept
If the settings on the configuration screen are correct:
Result:
– The “Configuration” program will terminate, and the parameters set will be accepted by the newly
started “Operation” program.
Check whether the correct short code and the correct reeving number have been selected on the
operating screen.
4.03 LIEBHERR 441

028367-00 4.04 Safety equipment
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4.04 Safety equipment 028367-00
1 General
1.1 Safety systems

The crane operator is obligated before every crane operation to ensure that the safety devices are
functioning.
WARNING
Danger of accident from defective warning and safety systems!
Operating the crane with defective warning and safety systems can lead to life-threatening accidents!
Make sure that all warning and safety systems are functioning.
Make sure that the overload protection is functioning.
1.1.1 Checking overload protection

If the telescopic boom without a load and lifting equipment is fully telescoped in and horizontally
aligned, then the LICCON must show approximately the following:
– Load 0 t
– Telescopic boom length
– Telescopic boom angle 0°
1.2 Levelling instruments

To ensure the working safety of the crane, the crane must be aligned horizontally on level ground with
sufficient load bearing capacity.
WARNING
Risk of accident due to toppling crane!
If the crane is not aligned horizontally, it may tip over. The maximum permitted deviation from the
horizontal position of the crane is ± 0.5 % (± 0.3°).
It is imperative that the crane is aligned in horizontal direction!
1.2.1 Leveling instruments on the chassis with BTT, illustration 1

For leveling with the BTT, the horizontal alignment of the crane is shown graphically as well as
numerically on the display of the BTT, see Crane operating instructions, chapter 3.05 and chapter
5.31.
1.2.2 Leveling instruments on the chassis with support control unit, illustration 2
For leveling with the support control unit, one support control unit with an electronic incline display is
installed on each of the two sides of the vehicle, see Crane operating instructions, chapter 3.01 and
chapter 3.05.
1.2.3 Leveling instrument on the superstructure

The horizontal alignment of the crane is displayed in the LICCON computer system both graphically
and numerically, see Crane operating instructions, chapter 4.02.
2 LICCON computer system

The LICCON computer system is a system for controlling and monitoring mobile cranes. In addition to
the overload protection (Load moment limiter LMB) there are a number of application programs that
can be used for controlling and monitoring the crane movements, see Crane operating instructions,
chapter 4.02.
4.04 LIEBHERR 443

2.1 Overload protection

The relevant sensors for the overload protection are:
– Length sensors
– Angle sensors
– Pressure sensors
The electronic overload protection turns all load moment increasing crane movements off if the
permissible load moment is being exceeded. Only load moment decreasing movements can then be
carried out.
DANGER
Risk of accident!
The presence of the overload protection does not relieve the crane operator of his obligation for care
and attention.
Before lifting a load, determine its approximate weight, and with the help of the load chart, decide
whether the crane is in a position to carry out this job.
The overload protection cannot cover all possible operational conditions.
DANGER
Danger of accident due to incorrect operation of the crane!
Due to incorrect operation of the crane, the overload protection does not become effective or the shut
off does not occur quickly enough. In these cases, accidents are possible despite an installed
overload protection!
Be especially vigilant!
The overload protection registers, but:

– does not turn off, for example the wind speed,
– does not monitor, for example the crane incline,
– does not monitor, for example the turn angle of the turntable.
The overload protection does not register:
– the hooking of the load or the load tackle,
– excessive delay forces,
– loads falling onto the rope,
– angular pull,
– driving the crane on ground with large slope,
– collapsing ground.
DANGER
Risk of accident due to crane toppling over or destruction of the crane!
The overload protection is a device according to EN 13000. It may not be used as an operational
shut off device for crane movements of any kind.
The overload protection must be adjusted to the current equipment configuration of the crane
before crane operation to match the load chart. Only that way can it fulfill its protective task.
The crane operator must meet his duty of caution and attention, despite the overload protection.
2.1.1 Failure of the overload protection
DANGER
Serious risk of accidents!
If the LICCON computer system is no longer functioning properly because of one or more errors,
crane operation is prohibited!
It is imperative that the next Liebherr Service location or Liebherr-Werk Ehingen is contacted!
444 LIEBHERR 4.04

2.1.2 Procedure to follow in case of a problem

Basically, all conditions in the load charts must be strictly adhered to, even those not monitored by the
LMB:
– The exact weight of the load, including load tackle, must be known.
– The condition of the boom and the boom geometry must be known and must agree with the stated
values in the corresponding load chart.
The boom length and boom radius must be measured manually.
– It must be ensured that the telescopic boom has been pinned.
Note
In the case of LICCON monitor failure, touch display failure or failure of one or more IO modules,
consult LIEBHERR Service.
2.1.3 Ending a load lift

If the problem cannot be remedied using these measures:
– Before continuing the load lift, contact the nearest Liebherr Service center or the Liebherr-Werk in
Ehingen.
If this is not possible, then the load lift can be completed with utmost caution, as follows:
– All values that are needed for determining the equipment configuration and the associated load
chart must be measured or manually determined.
DANGER
Risk of accident due to overloading the crane!
The weight of the load, including hook and attachment equipment must be known!
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3 Safety devices on the crane
3.1 Wind warning device

The wind warning appears in the operating view of the LICCON computer system.
If the actual wind speed value exceeds the displayed maximum value, the “Wind
warning” icon 1 starts to flash, and the acoustic alarm “Short horn” sounds. But there is no shut off of
crane movements.
WARNING
Danger of accidents of permissible wind speed is exceeded!
There is no automatic shut off of crane movements.
Stop crane operation and place down the boom.
3.2 Hoist limit switch “Hoist top”

The hoist limit switch is intended to prevent the hook block from colliding with the boom head.
Before every crane application, the function of the hoist limit switch must be checked by running
against the switch weight with the hook block.
When the hoist limit switch is actuated, the icon 2 appears in the operations screen. The crane
movements “Spool up winch”, “Luff telescopic boom down” and “Telescope out” are switched off.
WARNING
Risk of accident due to crane toppling over or destruction of the crane!
During crane operation bypass the hoist limit switch only with the set up key D if a guide can
monitor exactly the distance between the hook block and the boom head. The guide must be in
direct contact with the crane operator.
Carry out hoist movement with maximum caution and minimum speed.
In emergency situations, only an authorized person may bypass the hoist limit switch.
Do not use the hoist limit switch as an operational shut off function.
Always use the full length of the hoist limit switch weight chain.
Hang the limit switch weight always into the rope strand leading to the rope fixed point.
3.3 Limit switch winch spooled out

Note
Only for cranes with cam limit switch.
The cam limit switch installed in the winch turns “Winch spool out” off if there are only 3 rope coils
remaining on the winch.
WARNING
Risk of accident due to falling load!
If the following instructions are not observed, the rope attachment may be torn out causing the load to
topple.
The cam limit switch must turn off when there are 3 cable coils remaining on the winch!
If the hoist rope is spooled up during assembly, please ensure that the rope end remains in front
of the winch and is not pulled over the winch. If the rope end is pulled over the winch by another
rotation, the cam-type limit switch must be reset!
If a new rope is used, the cam limit switch must be reset!
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3.4 Limit switch winch spooled out

Note
Only for cranes with winch turn sensor.
The winch turn sensor is adjusted in the factory. If used properly, the winch speed sensor will not
need readjustment.
Note
Minimum rope coils on the shut off point!
For the winches, a minimum of 4 rope coils are set on the winch turn sensor.
WARNING
The load can fall off!
If the wind speed sensor does not turn off on the minimum rope coil, then the rope mount can be
ripped out and the load can fall down. Personnel can be severely injured or killed!
Crane operation with an incorrectly or non-adjusted winch is strictly prohibited!
Make sure that the winches are properly adjusted. Check the shut off without a load on the hook.
If it is found during operation or when changing a rope that there is no shut off at the minimum rope
coil:
Have the winch speed sensor readjusted by Liebherr Service.
WARNING
The load can fall off!
If the rope is not spooled up or out properly, then the turn sensor can no longer turn off controllably!
The load can fall down and personnel can be severely injured or killed!
Do not pull the end of rope underneath the winch by spooling the rope winch up!
Do not pull the rope from the “stationary” winch!
3.4.1 Checking the shut off of minimum rope coils
Note
If the “spool out” crane movement does not turn off at minimum rope coil: Have the winch speed
sensor readjusted by Liebherr Service.
Spool the winches out slowly and check the shut off point by carefully running to the 4 minimum
rope coils.
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4 Safety systems
4.1 EMERGENCY OFF switch*

If the EMERGENCY OFF switch 350 or the EMERGENCY OFF switch 651 on the BKE in the crane
operator's cab is operated, the motor and the electrical crane control are turned off. Every carried out
movement can be stopped immediately.
After operating the EMERGENCY OFF switch 350, a release can only be made by an authorized
person with a key and ignition “off”.
After the EMERGENCY OFF switch 651 has been operated, releasing takes place by rotating the
EMERGENCY OFF switch 651 and turning the ignition “off”.
Note
Only use the EMERGENCY OFF switch in the event of a clear emergency!
Use of the EMERGENCY OFF switch for normal operation is not permitted!
4.2 Control release

The seat contact button 301 shuts down the crane control as soon as the crane operator gets up from
the seat.
This prevents unintended crane movements by accidentally touching the master switch when getting
in or out of the cab.
The button 401 and button 421 bypass the seat contact button 301 if it becomes necessary for the
operator to work standing up.
4.3 Hydraulic safety valves

A distinction is made between two types:
– Pressure limitation valves against pipe and hose breaks
– Shut off valves in the luffing cylinder and in the support cylinders
4.4 Catch bar

Note
Only for cranes with folding jib.
The catch bar 40 on the telescopic boom articulated piece is a mechanical safety device!
WARNING
Danger of fatal injuries due to toppling folding jib!
As a result of improperly mounted, damaged or non-existing catch bar 40 on the telescopic boom
pivot section, the folding jib – due to an assembly error – can fall down and cause fatal injuries.
Before folding jib assembly, make sure that the catch bar 40 is properly mounted on the telescopic
boom pivot section and that it is not damaged.
The catch bar 40 is a mechanical safety device. For that reason, it is prohibited to change the
catch bar 40 in any way.
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4.5 Luffing lattice jib limit switch

Note
Only for cranes with luffing lattice jib.
For operation with the luffing lattice jib, limit switches monitor the “steepest position” and the “lowest
position”.
WARNING
Danger of toppling or destroying the crane!
If the crane movement is stopped by the limit switch, then the load forces cannot be absorbed by the
control!
The boom system can become unstable and the crane can topple over or be destroyed!
Do not use the hoist limit switch as an operational shut off device!
4.6 Mechanical relapse retainer on the luffing lattice jib

Note
Only for cranes with luffing lattice jib.
The mechanical relapse retainer prevents the luffing lattice jib from tipping backward in the event of a
failure of the limit switch luffing lattice jib “steepest position”.
WARNING
The mechanical relapse retainer no longer functions if the oscillation guard moves with difficulty!
The luffing lattice jib can tip backwards uncontrolled and cause the crane to topple over!
Crane operation with hard to move oscillation guard is prohibited!
Check the oscillation guard before erecting the luffing lattice jib!
4.04 LIEBHERR 453

026696-01 4.05 Crane operation
B196011
454 LIEBHERR 4.05

4.05 Crane operation 026696-01
1 General
– The crane is supported and aligned in horizontal direction according to the data in the load chart.
– The step at the entry of the crane operator's cab is moved out.
– The counterweight is attached and secured according to the data in the load chart.
– The crane engine is running.
– The hook block is correctly reeved as shown in reeving plan.
– All safety devices have been adjusted according to the data in the load chart.
– There are no persons or objects in the danger zone.
DANGER
Risk of accident!
In order to protect the crane and reduce the danger of accidents always use the master switch
slowly and sensitively.
Ensure that there are no obstacles in the crane's working area and no persons in the danger zone.
Give a short warning signal (horn) before starting a crane movement.
1.1 Superstructure
1.1.1 Locking the upper carriage

For crane operation only “to the rear” or when “driving with the equipment in place”, mechanically lock
the superstructure to the chassis.
Note
LICCON overload protection
The release of LICCON overload protection can only happen if the superstructure is properly
locked to the chassis.

Result:
– The locking mechanism of the superstructure is locked.
The icon 1 appears on the LICCON monitor.
1.1.2 Releasing the superstructure locking mechanism

Once the superstructure is locked:
Press the button 369 again.
Result:
– The locking mechanism of the superstructure is unlocked.
4.05 LIEBHERR 455

B196011
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1.2 Engine rpm
1.2.1 Locking the engine RPM

Locking engine RPM relieves the crane operator if he needs to work for an extended period with
constant RPM. The engine throttle can be locked in any position.
Press the pedal 377 down for the engine regulation until the desired RPM is reached.
or
Result:
– The pedal 377 is locked.
1.2.2 Releasing the engine rpm lock

If the engine rpm is locked:
or
Result:
– Locking is removed.
4.05 LIEBHERR 457

B196011
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1.3 “Power Plus” rapid gear

Note
Please note!
If a crane movement has reached its maximum speed due to the current utilization, then no speed
increase is possible by adding the rapid gear.
If the total power requirement of all actuated crane movements is larger than the available power,
then those crane movements are reduced which require the most power.
If another crane movement is added or taken back to one or more actuated crane movements
then this has an influence on the other movements. For that reason, we recommend in situations
in which an interference of the individual crane movements is troublesome, not to add the rapid
gear or to turn the rapid gear off.
1.3.1 Turning on “Power Plus” rapid gear

Using the button 402 or the button 422 will increase the speed of the crane movement for “luffing
up” and “lift / lower”.
DANGER
Accident hazard in the event of one to three strand reeving!
Do not turn the rapid gear on if the crane is loaded to more than 50 % of its maximum permitted
load carrying capacity for the respective radius.

or
Result:
– Rapid gear is turned on.
The icon 2 appears on the LICCON monitor.
1.3.2 Turning off “Power Plus” rapid gear

When rapid gear is turned on:
or
Result:
– Rapid gear is turned off.
The icon 2 turns off on the LICCON monitor.
4.05 LIEBHERR 459

B196011
460 LIEBHERR 4.05

1.4 Vibration sensor

By adding the vibration sensor, a crane movements can be detected by vibration of the master switch.
Make sure that the following prerequisite is met:
– The seat contact button 301 is actuated.
1.4.1 Winch 1
Result:
– The vibration sensor 421 is turned on.
When the vibration sensor 421 is turned on:

Result:
– The vibration sensor 421 is turned off.
1.4.2 Winch 2 or slewing gear

If winch 2 and the slewing gear are operated, the vibration sensor 403 will react to the first deflecting
movement.
Result:
– The vibration sensor 403 is turned on.
When the vibration sensor 401 is turned on:

Result:
– The vibration sensor 403 is turned off.
4.05 LIEBHERR 461

B196012
462 LIEBHERR 4.05

2 LICCON computer system

2.1 The crane engine is running.

– The batteries are charged by the alternator.
– A stable voltage is present.
The electric crane control system and the LICCON computer system are turned on automatically. A
self test of the LICCON computer system follows.
Await the self test.
Result:
– After a few seconds the configuration screen appears on the monitor.
Troubleshooting
The configuration screen does not appear on the monitor?
An error was detected during the self test of the LICCON computer system.
2.2 Stand-by mode

No crane movements are possible. See Crane operating instructions, chapter 4.02, section “LICCON
computer system in stand-by mode”.
4.05 LIEBHERR 463

B196013
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3 Luffing
Speed of crane movement “Luffing” is controlled by the deflection of master switch 1 420 and by the
pedal 377 of the engine control.
DANGER
Risk of overloading and/or toppling the crane!
If an attempt to lift a load with the hoist gear causes the LICCON overload protection to turn off,
then the load may not be lifted by luffing up the boom.
3.1 Luffing the telescopic boom

In the “Control Parameter program”, it is possible to preselect the maximum luffing speed of the
telescopic boom.
See Crane operating instructions, chapter 4.02, section “Control Parameter”.
3.1.1 Luffing the telescopic boom on cranes with one winch

– The switch 430 is at position left “luffing telescopic boom”.
– The seat contact button is actuated.
Deflect the master switch 1 420 in direction X-.
Result:
– The telescopic boom is luffed up.
Deflect the master switch 1 420 in direction X+.

Result:
– The telescopic boom is luffed down.
3.1.2 Luffing the telescopic boom on cranes with two winches

– The switch 430 is set to center position “luffing the telescopic boom”.
Result:
– The telescopic boom is luffed up.

Result:
– The telescopic boom is luffed down.
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B196013
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3.2 Luffing the folding jib*

– the switch 430 is set to position right “luff folding jib”
Result:
– Folding jib is raised.

Result:
– Folding jib is raised.
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4 Lifting / lowering
CAUTION
Danger of damaging the hoist rope when spooling up and/or reeling off!
Do not allow slack cable to build up.
Speed of crane movement “Lifting” is controlled by the deflection of the respective master switch and
by the pedal 377 of the engine control.
In the “Control Parameter” program, it is possible to preselect the maximum winch speed. It is also
possible to deactivate or activate the individual winches.
See Crane operating instructions, chapter 4.02, section “Control Parameter”.
4.1 Lifting / lowering winch 1

The winch icon 3 shows that winch 1 is turning, even when because of multiple reeving and low
speed, no hook movement is visible.
Deflect master switch 1 420 in direction Y+.
Result:
– Winch 1 unwinds and the load is lowered.
Deflect master switch 1 420 in direction Y-.

Result:
– Winch 1 unwinds and the load is lifted.
4.2 Lifting / lowering winch 2

The winch icon 4 shows that winch 2 is turning, even when because of multiple reeving and low
speed, no hook movement is visible.
Deflect master switch 2 400 in direction Y+.
Result:
– Winch 2 unwinds and the load is lowered.
Deflect master switch 2 400 in direction Y-.

Result:
– Winch 2 unwinds and the load is lifted.
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5 Turning
The speed of the “turning” crane movement is controlled via the deflection of master switch 2 400 and
via the pedal 377 of the engine regulation.
The basic principle is that with a longer boom and a heavier load, the crane should be operated at
lower speeds.
In the “Control Parameter” program, it is possible to preselect the maximum rotational speed.
See Crane operating instructions, chapter 4.02 “LICCON computer system”, section “Control
Parameters”.
The load chart manual gives the maximum slewing speeds in percentages. These values depend on
the boom length and the operating mode, and may not be exceed under any circumstances.
5.1 Turning the crane superstructure

Ensure that the superstructure is unpinned before initiating the turning movement.
DANGER
Ensure that there are no obstacles in the crane's working area and no persons in the danger zone.
Give a short warning signal (horn) before starting a crane movement.
When turning with a load, perform the turning manoeuvre very carefully and apply the brakes.

Result:
– The crane superstructure turns to the right.

Result:
– The crane superstructure turns to the left.
4.05 LIEBHERR 471

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5.2 Slewing gear, General

This crane is equipped with a “tensioned slewing gear”. With a “tensioned slewing gear” the braking
effect starts as soon as master switch 2 400 is moved towards the neutral position. The parking brake
is released as soon as master switch 2 400 is moved away from the neutral position.
5.2.1 Switching parking brake on/off

If the parking brake is off, then the load can be held by the slewing gear brake 374.
The parking brake switches on automatically if:
– The seat contact button 301 is actuated.
The parking brake can not be turned off if:
– The slewing gear was turned off by the sliding beam monitoring.
– The slewing gear was turned off by the LICCON overload protection.
– The working range limitation is active.
Turn switch 411 toward the right.
Result:
– Parking brake is switched off.
Turn switch 411 toward the left.

Result:
– The parking brake is locked on.
5.3 Switching the slewing gear to coasting

In order to position the boom over the load more easily, the slewing gear can be switched to coasting.
The master switch 2 400 may not be deflected while doing so.
The slewing gear cannot be switched to coasting in these situations:
– The slewing gear was turned off by the sliding beam monitoring.
– The slewing gear was turned off by the LICCON overload protection.
– The working range limitation is active.
Press the foot button 375.
Result:
– The slewing gear is switched to coasting.
Troubleshooting
With the slewing gear released, the superstructure slews unintentionally to the side (for example
because of wind).
Do not release the foot button 375.
Deflect the master switch 2 400 in slewing direction and then release the foot button 375.
Slow down the slewing movement by slowly resetting the master switch 2 400.
4.05 LIEBHERR 473

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5.4 Applying the slewing gear brake

CAUTION
Risk of damaging crane or roller slewing ring!
The slewing gear brake cannot brake all the torque.
For that reason the slewing gear brake 374 must only be used at minimal rotation speeds, in other
words with master switch 2 400 almost at the neutral position.
Do not brake the slewing movement of the crane by moving master switch 2 400 abruptly to the
neutral position and/or by abruptly applying the slewing gear brake 374!
The slewing gear brake 374 is only to be used in the following situations.
5.4.1 Starting out in strong side wind

When turning against the wind in strong side wind and with a long boom system, then the
superstructure will turn into the opposite direction due to leakage in the hydraulic motor.
This can be avoided as follows:
Actuate the slewing gear brake 374 and move master switch 2 400 to the desired turning direction.
Slowly release the slewing gear brake 374 until the superstructure turns in the desired slewing
direction.
5.4.2 Stop the slewing movement in strong side wind

Slow down the crane with master switch 2 400 to minimum turning speed.
Apply the slewing gear brake 374 carefully, until the crane has come to a standstill at the desired
position.
4.05 LIEBHERR 475

B196013
476 LIEBHERR 4.05

6 Telescoping
6.1 Control of crane movement
6.1.1 Cranes with one winch

Speed of the crane movement is controlled by the deflection of the master switch 2 400 and by the
pedal of the engine regulation 377.
Move master switch 2 400 in direction Y+ (forward).
Result:
– The telescopic boom is telescoped out.
Move master switch 2 400 in direction Y- (backward).

Result:
– The telescopic boom is telescoped in.
6.1.2 Cranes with two winches*

Speed of crane movement is controlled by the deflection of the master switch 1 420 and by the
pedal 377 of the engine control.
– The switch 430 is set to position left “telescoping”.
Move master switch 1 420 in direction X+ (toward the right).
Result:
Move master switch 1 420 in direction X- (toward the left).

Result:
4.05 LIEBHERR 477

B196273
478 LIEBHERR 4.05

6.2 General
The “Telematik” automatic telescopic boom control system consists of:
– The dual action telescoping cylinder
– The hydraulically operated gripper pinning
– The hydraulically operated boom pinning
The gripper and boom pins are mechanically interlinked, in other words the telescope section can only
be unpinned when at the same time the gripper is locked with this telescope section.
In the LICCON telescoping screen the crane operator can see, in dynamic graphics, the pinning state
of the telescopic boom, the position of the individual telescopes in relation to each other, and the
extension status of the telescoping cylinder.
Due to the automatic telescoping procedure, the crane operator can easily telescope the telescoping
boom, as he does not have to concern himself with the pinning or unpinning of the telescoping
cylinder or the telescopes. The LICCON telescoping control system therefore makes possible very
straightforward telescoping, only the desired telescoping targets need to be entered into the system.
The LICCON telescoping control system decides the sequence in which the individual telescopes will
be moved in order to achieve the desired end state. After setting the desired telescoping targets, all
telescoping movements, as well as locking and unlocking, are carried out fully automatically.
The following procedures are carried out by the system:
– Locking and unlocking of the telescoping cylinder
– Pinning and unpinning of the telescopes
– Sequence for the telescopes to be telescoped in order to achieve the desired end state
This automatic process will however only be carried out as long as the master switch is operated.
The master switch determines the direction and the speed of the telescoping movement. In this way
the crane operator has continuous control over the crane.
The direction of the cylinder movement is set by the LICCON computer system.
If the telescopic boom is lengthened, with the result that currently unreachable telescopes must be
moved, then they must first be retracted until the last telescope to be moved is reached. In this case,
in order to lengthen the telescopic boom (telescope out), telescoping in must first take place.
The LICCON computer system displays the direction in which the next telescoping must be done. The
master switch must also be pressed to correspond to this direction setting. In this way the connection
between the direction of movement of the appropriate master switch and the telescope continues.
Thus it is possible to move to a telescoping target automatically without an operating screen. It is
therefore also not essential to keep watching the LICCON monitor all the time.
If the direction needs to be changed by the master switch, the telescopic boom remains stationary if
the current direction is to be maintained. This also means that the master switch must be moved in
the other direction. If there is no further movement in the other direction, this means that the telescope
target has been reached. This state is showing visually in the operations screen. If the master switch
is still being pressed, then after 3 to 5 seconds, the system switches to the telescoping screen.
4.05 LIEBHERR 479

B196016
480 LIEBHERR 4.05

6.3 Selecting the telescoping target

There are two options for selecting the telescoping target:
1.) Target selection through the configuration screen
2.) Target selection through the telescoping screen
6.3.1 Target selection through the configuration screen

Press the program key P0.
Result:
– The configuration screen appears on the LICCON monitor.
Using the arrow keys 4, move the cursor 1 to the left or the right into the column corresponding to
the desired telescopic boom length.
As supporting information, the currently selected column number 3 and the number of columns in the
table are shown. For example, 45(89) means 45 of 89 columns.
The status indicator (±) on the left next to the percentage extension condition value means:
– “+” the corresponding telescopic section must be pinned.
– “-” the corresponding telescopic section can be telescoped up to the percentage value of the
extension status value under load (according to the load chart).
The double arrow 2 at the left and/or right edge of this line points to additional columns in either
direction.
If the cursor 1 touches an edge marked with arrows, the next movement in this direction will display
the next load chart column(s).
The cursor 1 itself will be set on the next column, if possible in the middle.
A change in the telescoping target is only possible if the master switch is at neutral.
If no cursor appears in the configuration screen, this means that on the telescoping screen a boom
configuration that is not supported in the tables was selected and perhaps even started!
Result:
– The selected telescoping target will be activated.
– The selected column for the telescoping target concerned will be marked in bold along the side.
4.05 LIEBHERR 481

B196275
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6.3.2 Target selection through the telescoping screen

Press the program key P4.
Result:
– The telescoping screen appears on the LICCON monitor.
The selection of the telescoping target is achieved by pressing the function key assigned to the
telescope concerned several times. After every key press, the intended extension status of the
associated telescope changes to the next percentage value where there is a hole for pins.
In contrast to the configuration screen, the telescoping length is displayed immediately as a target,
without further confirmation, as soon as the function key is pressed. No confirmation is required, as
the assigned function keys do not have any other functions.
The appearance of a direction arrow in the automatic icon 9.2 immediately after a change in the
telescoping target can be interpreted as feedback.
If the blinking icon 2 appears on the LICCON monitor, then:
– The telescoping sections cannot be unpinned.
– The unpinned load is exceeded.
– No load chart present.
Result:
– The following appears on telescope 1: 0 %, 46 %, 92 % or 100 %.

Result:

Result:

Result:

Result:
4.05 LIEBHERR 483

B196275
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6.4 Telescoping to the selected target

If the desired telescoping target is set, then the direction in which the master switch must be deflected
is displayed on the operating screen and on the telescoping screen.
If the master switch is moved against the specified direction, the telescope remains stationary. The
default direction remains visible as a possible error criterion.
If the set telescoping target has been reached, then the telescopic boom remains stationary,
regardless of any movements of the master switch, and the markings on the set telescoping target
begin to blink. The target has thus been reached.
If the arrow 9.2 up appears in the automatic icon 9:
Move master switch forward in direction Y+.
Result:
If the arrow 9.2 down appears in the automatic icon 9:

Move master switch backward in direction Y-.
Result:
4.05 LIEBHERR 485

B196017
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6.5 Telescoping with the operating screen

The telescoping system is designed so that an experienced crane driver can telescope without the
telescoping screen, in other words using just the operating screen.
The crane operator receives information about the direction in which the master switch must be
moved from the arrow 5.3.2 in the icon 5.
If the crane operator attempts further telescoping once the telescoping target has been reached, then
there is an automatic switch-over from the operating screen to the telescoping screen. If the master
switch is still being pressed, then the markings on the set telescoping target flash. This means that the
telescoping target has been reached.
If the arrow 5.3.2 up appears in the icon 5:
Move master switch forward in direction Y+.
Result:
If the arrow 5.3.2 down appears in the automatic icon 5:

Move master switch backward in direction Y-.
Result:
Once the telescoping target is reached, icon A! 5.3.1 appears.

Press the master switch for another 3 seconds or so, until the telescope is resting on the bolt.
6.6 Aborting telescoping

Telescoping can be aborted at any time.
The bolts, the telescoping cylinders and the telescope remain where they were, in the last state they
were in when the master switch was still being pressed.
If desired, a new telescoping target can be set and telescoped to automatically.
It is also possible to proceed manually by switching over to manual operations.
6.7 Telescoping manually (emergency operation)

Manual telescoping is regarded as an exception mode, as automatic mode makes it possible to reach
any chosen extension state.
In manual telescoping, pinning and unpinning of the telescoping cylinder, and telescoping, must be
carried out manually.
The marking on the telescoping screen will indicate in which telescope the pinning device of the
telescoping cylinder is currently located.
The proximity to a telescope pin bore can be determined on the telescoping screen to an accuracy of
1%.
4.05 LIEBHERR 487

027940-02 4.06 Rope reeving
B108118
488 LIEBHERR 4.06

4.06 Rope reeving 027940-02
1 Wire ropes and rope end connections
1.1 Wire ropes

Please check if a rotating resistant or a non-rotating rope is required for the application. The type of
rope that is selected then determines the required type of rope end connections, see Crane operating
instructions, chapter 8.04.
Note
The correct choice and use of wire rope and rope end connections are decisive preconditions for
proper and accident-free crane operation!
DANGER
Danger of serious personnel injury and equipment damage!
Never use rotation-resistant ropes with a rotating rope end connection!
Never install a twist compensator / swivel!
1.2 Rope end connections

Rope end connections are grouped into:
– Rope end connections with rope clamp 8
For that, use a rope lock 1, see illustration 1.
– Rope end connections without rope clamp
For that, use a wedge lock 40, see illustration 2.
4.06 LIEBHERR 489

B110411
490 LIEBHERR 4.06

2 Reeving the hoist rope with the auxiliary reeving

rope
WARNING
Risk of falling!
The assembly personnel, due to an erroneous operation of the crane function or slip on the telescopic
boom, can fall and be killed!
The telescopic boom may only be accessed if the assembly personnel is protected with suitable
safety measures to prevent them from falling!
If retaining ropes are present on the telescopic boom, then the assembly personnel must hang an
approved fall arrest system to the retaining ropes of the telescopic boom on the left and right with
both snap hooks and secure themselves in case of falls. See crane operating instructions, chapter
2.04 and chapter 2.06!
Without appropriate safety measures, it is strictly prohibited to step on the telescopic boom!
If railings are present for the crane, then they must be brought into the corresponding position and
secured for assembly / disassembly.
Carry out all assembly work from a safe place!
2.1 Reeving procedure

– The crane is properly supported and horizontally aligned.
– The crane is ballasted according to the load chart.
– The LICCON overload protection has been set according to the load chart.
– The telescopic boom is fully telescoped in.
– The telescopic boom has been luffed to the rear or the side.
– The telescopic boom is luffed down in 0° position.
Wear approved fall arrest system and protective equipment, see Crane operating instructions,
chapter 2.04.
Install the hook device on the ladder, see Crane operating instructions, Chapter 2.06.
WARNING
Risk of falling!
Hang the ladder in such a way onto the hoist gear and on the telescopic boom that it cannot fall
over! See Crane operating instructions, chapter 2.06.
If no railing is installed on the crane superstructure:

Hang the ladder on the hoist gear and set it up safely, see Crane Operating instructions, Chapter
2.06.
If a railing is installed on the crane superstructure:
Set the railing on the crane superstructure into assembly / disassembly position, see Crane
operating instructions, chapter 2.06.
Secure the assembly personnel from falling: Hook assembly personnel with fall arrest system on
the respective fastening points, see Crane operating instructions, chapter 2.06.
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B110411
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With the auxiliary reeving rope 34, the hoist rope 31 can be reeved safely.
When a intake sleeve 33 is installed on the auxiliary reeving rope 34:
Connect the auxiliary reeving rope 34 with the hoist rope 31: Slide the intake sleeve 33 onto the
locking clamp 8 and close off with the sleeve plug 35.
When no intake sleeve 33 is installed on the auxiliary reeving rope 34:
Connect the auxiliary reeving rope 34 with the hoist rope 31: Open the chain lock 36, connect it
with the eyehook of the lock clamp 8 and close the chain lock 36.
Place the auxiliary reeving rope 34 forward over the pulley head.
Hang the ladder on the telescopic boom and set it up safely, see Crane Operating instructions,
Chapter 2.06.
Secure the assembly personnel from falling: Hook assembly personnel with fall arrest system on
the respective fastening points, see Crane operating instructions, chapter 2.06.
Remove the rope retaining pipe 14 and rope retaining pipe 15 on the pulley head.
Place the auxiliary reeving rope 34 over the upper rope pulley 13.
NOTICE
Danger of slack rope formation!
If the auxiliary reeving rope 34 is not held tight when spooling the winch out, slack rope can form on
the hoist rope 31!
Hold the auxiliary reeving rope 34 tight!
Slowly spool out the winch by deflecting the master switch and pull the auxiliary reeving
rope 34 with the hoist rope 31 over the upper rope pulley 13.
Detach the auxiliary reeving rope 34 on the hoist rope 31 and reeve the hoist rope 31 into the
hook block.
Insert and secure the rope retaining pipe 14 and the rope retaining pipe 15 on the pulley head.
4.06 LIEBHERR 493

B108124
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3 Reeving the hook block in and out
3.1 Reeving in the hook block
3.1.1 Preparing the hook block
NOTICE
Damage to the hoist rope!
An incorrectly reeved hoist rope or the incorrect selection of the rope fixed point can cause the hook
block not to hang vertically and thus cause damage to the hoist rope!
Always carry out the reeving of the hoist rope according to the reeving plan!
The rope fixed point on the hook block is to be selected in such a way that the last strand runs
parallel to the remaining rope strands, as much as possible!
Place the required hook block under the pulley head of the telescopic boom.
At the hook block 19, remove the spring retainers 18 for both rope retaining pins and pull them
both out.
WARNING
Risk of falling!
Reeve in the hoist rope, see section “Reeving the hoist rope with the auxiliary reeving rope”.
Insert the rope retaining pipes again and secure with spring retainers.
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3.1.2 Fastening the hoist rope
NOTICE
If the pin 3 has been assembled incorrectly, the hoist rope may rub against the pin 3 or on the linch
pin 2.
Always insert the pins 3 from “inside to outside” and secure from the outside, see fig. 1.
The rope lock 1 must be pinned in either at the pulley head or on the hook block and secured with
linch pins 2, depending on reeving.
Push the retaining pin 6 on the rope lock 1 in, move the lever 5 “downward” and hold it in this
position.
Result:
– The latch 4 will be swivelled downward.
Attach the rope end with the locking clamp 8 in the rope lock and pull the rope firmly
“downward” (in direction of arrow), until the locking clamp 8 is placed in the cone 7.
WARNING
Danger of accident due to incorrect mounting of locking clamp!
The locking clamp 8 must touch on the cone 7 after hanging it into the rope lock 1 and must be
secured by the latch 4!
Release the lever 5.

Result:
– The lever 5 returns to the initial position and is locked by the retaining pin 6.
4.06 LIEBHERR 497

B108124
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3.2 Unreeving the hook block

– The ground is level and of sufficient load carrying capacity.
3.2.1 Lowering the hook block
WARNING
Crushing of hands!
When guiding the hook block by hand, hands or fingers can be crushed!
When unreeving the hook block, it can topple over!
Use the handles in the safe area of the hook block!
Make sure the hook block is safely positioned!
Lower the hook block and set it on the ground.

Remove the hoist limit switch weight, see section “Removing the hoist limit switch weight”.
3.2.2 Detaching the hoist rope

Push in retaining pin 6 on the rope lock 1 move the lever 5 downward and hold it in this position.
Result:
– The latch 4 is moved to the side and the locking clamp 8 is released.
Push the hoist rope up and detach the locking clamp 8.

At the hook block 19, remove the spring retainers 18 for both rope retaining pins and pull both
rope retaining pins out, see section “Reeving the hoist rope with the assembly winch”
On the pulley head remove the spring retainers on the rope retaining pipe 14 and on the rope
retaining pipe 15 and pull the rope retaining pipes out, see section “Reeving the hoist rope with the
auxiliary reeving rope”
Unreeve the hoist rope from the hook block and the pulley head.
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4 Securing and removing the load hook*
4.1 Securing the load hook*
4.1.1 Assembling the load hook*

Place the load hook under the pulley head of the telescopic boom.
At the pulley head remove the spring retainers on the rope retaining pipe 14 and on the rope
retaining pipe 15 and pull the rope retaining pipe out.
WARNING
Risk of falling!
Place the hoist rope over the upper rope pulley 13, see section “Reeving the hoist rope with the
auxiliary reeving rope”.
Insert the rope retaining pipe 14 and the rope retaining pipe 15 and secure with spring retainers.
Pin the rope lock 1 in the load hook 26 and secure with spring retainers.
4.1.2 Fastening the hoist rope

Push the retaining pin 6 into the rope lock 1, move the lever 5 sideways and hold it in this position.
Result:
– The latch 4 is moved to the side.
Hang in the rope end with the locking clamp 8 in the rope lock and pull the rope firmly in the
direction of the arrow, until the locking clamp 8 contacts the cone 7.
WARNING
Danger of accident due to incorrect mounting of locking clamp!
The locking clamp 8 must touch on the cone 7 after hanging it into the rope lock 1 and must be
secured by the latch 4!
Release the lever 5.

Result:
– The lever 5 returns to the initial position and is locked by the retaining pin 6.
4.06 LIEBHERR 501

B108125
502 LIEBHERR 4.06

4.2 Removing the load hook*

– The ground is level and of sufficient load carrying capacity.
4.2.1 Lowering the load hook
WARNING
Crushing of hands!
When guiding the load hook by hand, hands or fingers can be crushed!
The load hook could roll away!
Make sure the load hook is safely positioned!
Place the load hook 26 on the ground.

Remove the hoist limit switch weight, see section “Removing the hoist limit switch weight”.
4.2.2 Detaching the hoist rope

Push the retaining pin 6 into the rope lock 1, move the lever 5 sideways and hold it in this position.
Result:
– The latch 4 is moved to the side and the locking clamp 8 is released.
Push the hoist rope in the direction of the load hook and detach the locking clamp 8.
At the pulley head remove the spring retainers on the rope retaining pipe 14 and on the rope
retaining pipe 15 and pull the rope retaining pipe out, see section “Reeving the hoist rope with the
assembly winch”.
Unreeve the hoist rope from the pulley head.
4.06 LIEBHERR 503

B106127
504 LIEBHERR 4.06

5 Attaching / removing the hoist limit switch weight
5.1 Attaching the hoist limit switch weight

The hoist limit switch weight 30 consists of 2 parts, which are pushed into each other:
– The weight 35.
– The carrier section 36.
Loosen and open the screw retainer 32.
WARNING
The hoist limit switch can fall down!
If the hoist limit switch weight is incorrectly assembled, components can fall down!
Do not replace the snap hook 33 with other parts, such as a shackle or similar!
When detaching or attaching the hoist limit switch weight 30 make sure that the weight 35 and the
carrier section 36 do not fall down!
Make sure that the curvature R of the carrier section 36 points to the hoist rope 34!
Make sure that the stubs 31 of the carrier section 36 touch on the weight 35!
Make sure that the screw retainer 32 can be turned to be closed from top to bottom, point K!
The attachment of the hoist limit switch weight 30 depends on the position of the rope fixed point.
Rope fixed point on the pulley head:
– In the event of multiple hoist rope reeving, the hoist limit switch weight 30 must always be laid
around the “stationary rope strand”, in other words around the rope strand that leads directly to the
cable lock.
Rope fixed point on hook block:
– The hoist limit switch weight 30 is laid around the outer strand which shows the least diagonal pull,
i.e. the one with the smallest angle between the hanging hoist limit switch weight and the hoist
rope.
Note
The chain 37 must be attached in full length during crane operation and may not be shortened.
Push the weight 35 with one hand on the hoist rope 34 and hold.
With the other hand, guide the carrier section 36 behind the hoist rope 34 and under the
weight 35. The curvature R of the carrier section 36 must point to the hoist rope 34.
Push the weight 35 on the carrier section 36.
Hang in the hoist limit switch weight 30 with the carrier section 36 in the snap hook 33.
The snap hook 33 must be secured with the screw retainer 32.
Close the screw retainer 32 on the snap hook 33.
4.06 LIEBHERR 505

B106127
506 LIEBHERR 4.06

5.2 Removing the hoist limit switch weight

WARNING
The hoist limit switch can fall down!
If the hoist limit switch weight is incorrectly removed, components can fall down!
Personnel can be severely injured!
When detaching or attaching the hoist limit switch weight 30 make sure that the weight 35 and the
carrier section 36 do not fall down!
It is prohibited for anyone to remain in the danger zone!
Release and open the screw retainer 32 on the snap hook 33.
Detach the hoist limit switch weight 30 from the snap hook 33.
Hold the weight 35 with one hand and with the other hand, push the carrier section 36 from the
weight 35.
Store the weight 35 and carrier section 36 safely.
4.06 LIEBHERR 507

B108119
508 LIEBHERR 4.06

6 Assembling / disassembling the wedge lock

– The rope clamp is cut off on the hoist rope.
– The hook block or the load hook are ready for assembly.
6.1 Installing the wedge lock

WARNING
Danger of fatal accidents due to falling load!
If an incorrect wedge lock 40 is used or if the wedge lock 40 is incorrectly assembled, the hoist rope
can rip off or the hoist rope can be pulled through the wedge lock 40!
The hook block and the load can fall down and kill personnel!
Use only a wedge lock 40 approved by Liebherrwerk Ehingen!
Assembling the wedge lock 40 correctly!
Place the hoist rope with the wedge 41 into the housing 43 in such a way that the rope strand runs
in the pull axle of the wedge lock 40!
The dead end of the rope must be secured by the clamp 42 to prevent it from being pulled
through!
It is prohibited for personnel to remain in the danger zone!
Take a matching wedge lock 40 from the tool box.

Place the hoist rope with the wedge 41 into the housing 43.
If possible, assemble the clamp 42 through the wedge 41 on the dead end of the rope.
NOTICE
If the pin 3 has been assembled incorrectly, the hoist rope may rub against the pin 3 or on the linch
pin 2.
Always insert the pins 3 from “inside to outside” and secure from the outside.
Pin and secure the wedge lock 40 on the fixed point of the pulley head or that of the hook block or
on the load hook, depending on the reeving plan.
6.2 Disassembling the wedge lock

Unpin the wedge lock 40 on the fixed point.
Remove the clamp 42 and pull the hoist rope with the wedge from the housing.
Store the wedge lock 40.
4.06 LIEBHERR 509

B108222
510 LIEBHERR 4.06

7 Crane operation with auxiliary block* on the

telescopic boom
7.1 Crane operation with auxiliary block*

For crane operation with auxiliary block 1, the following prerequisites are required:
– The TY guying has been disassembled (if present).
– The working floodlights on the telescopic boom have been disassembled.
Note
For crane operation with auxiliary block 1 on the telescopic boom, move only to the radius ranges,
which are present in the load chart!
NOTICE
Damage of hook block, auxiliary block or hoist rope!
If the following notes are not observed, the hook block 3, the hoist rope 2 or the auxiliary block 1 can
be damaged!
If the hoist limit switch chain on the hoist limit switch weight is too short, the hook block 3 can run on
the auxiliary block 1 when spooling up the hoist rope 2 and damage it severely.
Before crane operation with auxiliary block 1, assemble the longer hoist limit switch chain!
Before crane operation with auxiliary block 1, remove the rope protection pipes on the hook
block 3!
When the hook block 3 is on the ground, ensure that the hoist rope 2 remains in the pulleys!
For operation with auxiliary block 1, do not telescope the telescopic boom out and run only the
radii ranges, which are specified in the load chart!
Carry out crane operation with auxiliary block 1 carefully.
8 Rope reeving
Note
For reeving plans, see Crane operating instructions, chapter 4.15!
4.06 LIEBHERR 511

025976-01 4.07 Counterweight
B196427
512 LIEBHERR 4.07

4.07 Counterweight 025976-01
1 General
Before driving on public roads, the counterweight distribution must be made as described in chapter
3.04.
The counterweight plates are marked with their own weights.
DANGER
If a different counterweight than the one listed in the load chart is used, the crane may be damaged or
topple over.
Attach counterweight in accordance with the information in the load table!
1.1 Counterweight combinations

CAUTION
The crane may topple, if another counterweight combination is used than specified in the tables.
Counterweight combinations specified in the following tables must be applied!
Counterweight [t] Combination Individual weight

[t]
0 No counterweight 0.0

[t]
12 Counterweight plate 1 12

[t]
Counterweight plate 2 10

[t]
4.07 LIEBHERR 513


[t]

[t]

[t]

[t]

[t]
514 LIEBHERR 4.07


[t]
Auxiliary ballast 5 10
Auxiliary ballast 5 10
1.2 Checking the counterweight plates

DANGER
Risk of accident due to damaged counterweight plates!
If damaged counterweight plates are loaded, the stable seating of the counterweight plates can no
longer be guaranteed.
Replace damaged counterweight plates!
Before assembling or disassembling the counterweight plates, check visually for damage and foreign
matter.
When depositing the counterweight plate 1 on the centering cone 9 and stacking the counterweight
plates, make sure that no foreign matter gets between the counterweight plates.
4.07 LIEBHERR 515

B112121
516 LIEBHERR 4.07

1.3 Hanging the counterweight plates as a package

WARNING
Danger of accident due to incorrect fastening equipment!
Use only supplied fastening equipment 6!
It is prohibited for personnel to remain in the danger zone!
When the counterweight plate 1 and counterweight plate 2 is hung as a counterweight package, the
following must be observed:
– The counterweight plate 2 is placed on the counterweight plate 1.
– The pins 3 are inserted on both sides on points P1.
– The washers 4 and ring screws 5 is screwed on both sides on the pins 3.
– The fastening equipment 6 is properly hung.
Note
Parking position for pins 3, see illustration 2.
4.07 LIEBHERR 517

B196427
518 LIEBHERR 4.07

2 Assembly
2.1 General
– The transport vehicle with the counterweight plates is in the immediate vicinity of the supported
crane.
– The ballasting cylinders are fully retracted.
DANGER
In steep boom positions, for which no load values are given in the load charts, there is a danger of
toppling over when turning the crane superstructure! There is a particular risk if the support base has
been reduced or if the crane is supported with the sliding beams retracted.
The specifications in the load charts must be adhered to!
2.2 Stacking the counterweight plates on the vehicle

Start the engine.
Set LICCON overload protection according to the load chart and the counterweight assembled on
the turntable.
DANGER
Before the boom is lifted from the transportation position, the crane must be supported according to
the load chart and the LICCON overload protection must be set according to the valid load chart! The
boom lengths and boom projection radii specified in the load chart may not be exceeded during
ballasting! If this is not observed, there is a risk of accidents as the crane can topple over!
Comply with the load chart specifications!
The counterweight plate 1, as the load-bearing plate for the other counterweight plates, must always
be placed on the receptacle frame first.
Attach the counterweight plate 1 on the fastening ropes and place it on the centering cone 9 on
the storage frame using the own crane.
Place the required counterweight plates on the counterweight plate 1.
DANGER
If the auxiliary ballast 5 is attached only “on the right” or “only on the left”, the crane can topple over.
The auxiliary ballast 5 must always be attached in pairs on the right and on the left!
Attach the auxiliary ballast 5 on the right and on the left.
4.07 LIEBHERR 519

B196427
520 LIEBHERR 4.07

2.3 Picking the counterweight plates up

Rotate the crane superstructure until the small pointer 8 on the slewing ring aligns with the marked
bolt 6, see illustration 2.
Result:
– The ballast cylinders are now located next to the intake openings for the counterweight plate 1.

Result:
– The crane superstructure is locked with the crane chassis.
Press button 370 down until an acoustical signal sounds.

Result:
– The ballast cylinders are fully extended when the acoustic signal sounds.

Result:
– The crane superstructure is unlocked.
Carefully turn the crane superstructure to the right until the large pointer 7 on the slewing ring
aligns with the marked bolt 6, see illustration 1.
Result:
– The ballast cylinders are now retracted into the receptacles of the counterweight plate 1.

Result:
DANGER
Risk of accident!
No movement (lift/lower counterweight) may be operated until the crane superstructure is locked!
Push button 370 upward until an acoustical signal sounds.

Result:
– The ballast cylinders are fully retracted when the acoustic signal sounds.

Result:
The counterweight may also be installed directly to the counterweight frame with the assistance of an
auxiliary crane. Placing the counterweight on the crane chassis and turning the crane superstructure
may be omitted in this case, the remaining operation steps remain the same.
Set LICCON overload protection according to the load chart and the attached counterweight.
4.07 LIEBHERR 521

B196427
522 LIEBHERR 4.07

3 Disassembly of the counterweight plates
3.1 General
– The transport vehicle for the counterweight plate holder is in the immediate vicinity of the
supported crane.
DANGER
In steep boom positions, for which no load values are given in the load charts, there is a danger of
toppling over when turning the crane superstructure! There is a particular risk if the support base has
been reduced or if the crane is supported with the sliding beams retracted.
4.07 LIEBHERR 523

B196427
524 LIEBHERR 4.07

3.2 Removing the counterweight plates

Rotate the crane superstructure until the large pointer 7 on the slewing ring aligns with the marked
bolt 6, see illustration 1.
WARNING
Risk of accident!
The superstructure must be locked to the crane chassis, so that the counterweight can be set and
placed on the centering cone 9.
Lock the crane superstructure with the crane chassis.

Result:
Press button 370 down until an acoustical signal sounds.

Result:
– The ballast cylinders are fully extended when the acoustic signal sounds.

Result:
Turn the crane superstructure to the left until the small pointer 8 on the slewing ring aligns with the
marked bolt 6, see illustration 2.
Result:
– The ballast cylinders are now located next to the retraction openings of the counterweight plates.

Result:
Push button 370 upward until an acoustical signal sounds.

Result:
– The ballast cylinders are fully retracted when the acoustic signal sounds.

Result:
4.07 LIEBHERR 525

B196427
526 LIEBHERR 4.07

3.3 Lifting the individual counterweight plates from the vehicle frame
with the own crane
Adjust the LICCON overload protection according to the load chart and ballasted counterweights.
DANGER
The boom lengths and boom projection radii specified in the load chart may not be exceeded. If this is
not observed, there is a risk of accidents as the crane can topple over!
The boom lengths and boom projection radii noted in the load chart must be strictly observed!
Individually attach counterweight plates to the cables and deposit these on the transport vehicle
with the crane.
3.4 Driving with counterweight plates placed on vehicle frame

The axle loads increase with the counterweight plates on the vehicle.
DANGER
Exceeding the axle load and total weight increases the risk of accidents!
If the axle loads and the overall vehicle weight are excessively increased due to non-compliance, the
brake performance is also reduced in direct proportion to the excess weight! The steering system,
service brake, parking brake and retarder no longer meet EU guidelines!
Do not exceed the specified axle load or total weight under any circumstances!
4.07 LIEBHERR 527

026079-08 4.08 Working with a load
B195219
528 LIEBHERR 4.08

4.08 Working with a load 026079-08
1 Technical safety instructions for working with a load

For more information, see chapter 2.04.
WARNING
For steep boom positions, for which no loads are specified in the load charts there is a risk of the
crane superstructure toppling when turning “backward”, i.e. towards the counterweight side! There is a
particular danger if the support base has been reduced and supported with the sliding beams
retracted!
The radii specified in the load chart must be observed!
WARNING
Danger of accident due to faulty operation!
If the reeving number on the pulley head is less than the reeving number set on the LICCON
computer system and if the load is lifted with the luffing gear, it can result in an overload of the hoist
rope, as a result, the hoist rope can rip, causing the load to drop!
Always comply with the reeving numbers specified in the load chart for maximum loads!
The reeving on the pulley head and the reeving set on the LICCON computer system must match,
otherwise crane operation is prohibited!
DANGER
Danger of fatal accidents due falling load!
If the required number of three coils is fallen below (for example due to a technical defect), the hoist
rope is ripped from the winch drum and the load falls down.
The crane operator must ensure that there are always at least three windings on the winch drum!
Always comply with the maximum load specified in the load chart.
The weight of the hook block according the load chart must be taken into account.
For the lift, use the hook block which is suited best for the existing equipment configuration in
connection with the load chart.
Initiate all crane movements carefully and also use the brakes carefully during crane movements.
That way you can avoid a swinging or pendulum motion in the suspended load.
4.08 LIEBHERR 529

2 Checks before starting to work with the crane

Before starting work with the crane, the crane operator must carry out a further inspection to satisfy
himself about the crane's operational safety:
– Check that the crane is properly supported and level.
– Check that all values in the load chart that apply to the current equipment configuration have been
entered and met.
– Ensure that there are no people or objects in the crane danger zone.
WARNING
Danger of accidents when turning the crane superstructure!
By turning the crane superstructure in restricted space conditions on the job site, especially in the rear
area of the counterweight and towards the chassis, personnel can be crushed and severely injured or
killed!
Give a short warning signal (horn) before starting a slewing movement!
Ensure before starting any slewing movement that there are no people or objects in the danger
zone!
2.1 Visual check for damage

WARNING
Risk of accident!
If the crane is operated despite existing defects, personnel can be severely injured or killed!
In the event of deficiencies that threaten operational safety, stop crane operation immediately!
The following deficiencies threaten the crane's operational safety:

– Damage to load-bearing parts of the crane design, such as booms, supports etc.
– Failure of the hoist gear brake and consequent slipping of the load
– Functional failures in the crane control system
– Functional failures in the indicator and warning lights
– Damage to the hoist ropes
– Functional failures in the safety devices
– Leakages on safety relevant components of the crane hydraulic
Inform the appropriate supervisor about the deficiencies on the crane and also inform your relief when
crane operators are changed.
2.2 Telescopic boom distortion because of sunshine on one side

A temperature difference occurs between the side facing the sun and the side facing away from the
sun for cranes with telescopic boom. This causes telescopic boom side distortion, which can reduce
the load-bearing capacity of the telescopic boom. For example, a temperature difference between the
two boom sides of 30 °C and a boom length of 60 m results in a length difference caused by the
temperature difference between the two sides of the telescopic boom of approximately 22 mm.
Particularly with narrow boom parts, this causes the profiles to bend sideways!
If the maximum load is being fully utilised, particularly when a telescopic boom extension such as a
lattice jib, luffing lattice jib or folding jib is being used, the equipment must be visually inspected before
picking up the load in order to ensure that the boom is not showing signs of side deformation because
the sun shining on one side.
WARNING
Risk of accident because of component overloading!
If the telescopic boom has become distorted because of one-sided sunlight, this can cause
component overloading and therefore accidents!
Turn crane so that both sides of the boom are brought to about the same temperature, therefore
preventing side deformation!
530 LIEBHERR 4.08

3 Crane movement - Telescoping

If the telescopic boom is telescoped, particularly with the auxiliary boom or telescopic boom
extension, before the telescoping procedure, ensure that:
– The telescopic boom is evenly warmed up by solar radiation.
– There is no strong side wind.
WARNING
Damage of the telescopic boom or the hoist rope!
If these 3 factors are not adhered to, damage of the telescopic boom or the hoist rope can occur and
lead to accidents!
Support the crane properly and align it horizontally!
Keep both sides of the boom at about the same temperature!
Telescope only to the permissible wind speed according to the load chart!
If the actual wind speed is higher than the permissible wind speed noted on the load chart,
telescoping is prohibited!
4.08 LIEBHERR 531

B108127
532 LIEBHERR 4.08

4 Taking on a load
The crane must always be operated in such a way that its load-bearing parts are not destroyed or
damaged and its stability is ensured.
– The crane is supported and horizontally aligned.
– The counterweight is installed according to the load chart.
– The hook block or the load hook is correctly reeved.
4.1 Attaching the load

WARNING
If the following conditions are not met, the crane can topple over and cause fatal injuries!
Observe own weight of the load tackle!
Observe own weight of the load tackle!
The maximum permissible inclination of the strands fastened on double hooks in the hook jaws
amounts to 45°. See illustration 1.
On single hooks, operation with inclined strands in the hook jaws is prohibited!
If necessary, use tackle with a suspension link 10! The maximum permissible incline is 60°. See
illustration 2.
4.08 LIEBHERR 533

B102716
534 LIEBHERR 4.08

4.2 Lifting the load

WARNING
Danger of crushing for people in the load zone!
If personnel are located between the load to be lifted and a possible interfering edge (such as a wall
of a building or similar) when the load is lifted, personnel can be severely injured or killed!
Before lifting the load it must be ensured that there are no persons within the danger zone!
It is prohibited for anyone to be under the load! Keep a safety distance!
Swinging of the load is prohibited!
Exercise extreme caution when lifting a load!
WARNING
If an attempt to lift a load above the hoist gear causes the LICCON overload protection to switch off,
then the load must not be lifted by raising the boom. This leads to overloading and toppling of the
crane!
Do not lift the load by luffing up the boom from the ground!
Note
When using the assembly winch* observe the following:
The assembly winch* should only be used for assembly, and not for lifting loads!
Lifting of loads with the auxiliary winch is prohibited!
If the cable is manually attached to the load to be raised by an assistant:

– Make sure that the assistant's hands are not crushed between the load and the cable by the tautly
pulled ropes.
– Make sure that the assistant's body parts (hands, legs etc.) are not crushed by a pendulum
movement of the load during lifting.
4.3 Angular pull

WARNING
Angular pulling can destroy the crane or cause it to topple over!
The hook block must always be attached vertically over the center of gravity of the load to be
lifted!
The crane is designed only to lift loads vertically. During diagonal pulling, regardless of whether this is
done in the same direction as the boom or diagonally, horizontal forces are generated in addition to
the vertical ones, for which the boom is not designed.
4.08 LIEBHERR 535

B102717
536 LIEBHERR 4.08

4.4 Breaking away fixed loads

WARNING
Ripping stuck loads free can destroy the crane or cause it to topple over!
Ripping stuck loads free is prohibited!
5 Crane operation
The maximum load-bearing capacity is not just limited by stability, but in many cases a load-bearing
component breaks when the crane is overloaded before the crane topples over. Particularly
components that are susceptible to buckling such as the telescopic boom may fail suddenly without
showing signs of distortion beforehand if the crane is overloaded.
WARNING
Danger of accidents for cranes with luffing cylinders!
When the luffing cylinder is on block position, the overload protection is not functioning!
Crane operation at block position of luffing cylinders is prohibited!
5.1 General
A suspended load must always be kept under control. A fundamental requirement for this is the safe
and delicate control of the crane's functions.
WARNING
Risk of accident due to swaying loads!
A swaying load can damage the crane and cause it to topple!
All crane movements must be executed slowly and delicately!
Initiate all crane movements slowly!
Apply the brakes slowly in all crane movements!
Crane operation with swaying loads is prohibited!
NOTICE
Damage of rope pulleys!
Place down hook blocks, boom, folding jibs, auxiliary booms and boom noses in such a way that
the rope pulleys do not lie on the ground and are damaged!
5.2 Guiding the load

The use of guide ropes is recommended to help the crane operator to manage the load more
precisely and to prevent the load from swaying. This will prevent undesirable movements of the load
and consequent damage.
5.3 Danger of being crushed!

WARNING
Extreme care is needed when lowering a load! Mortal danger exists for personnel in the immediate
area of the load being lowered!
Standing under a suspended loads is strictly prohibited!
4.08 LIEBHERR 537

5.4 Working in the vicinity of electricity transmission lines

DANGER
Risk of accident!
Failure to observe the following notes can lead to damage!
Note the following points carefully!
If there are electricity transmission lines in the immediate vicinity of the building site, these must be
switched off by qualified electricians. If this is not possible, the danger area must be covered over or
cordoned off. If even these measures cannot be carried out, the following safety distances must be
maintained:
Rated voltage Minimum distance

Up to 1 kV 1m
1 kV to 110 kV 3m
110 kV to 220 kV 4m
220 kV to 380 kV 5m
Rated voltage not known 5m
If the crane becomes electrified despite having taken all necessary precautions, proceed as follows:
– Remain calm!
– Stay inside the crane driver's cab!
– Warn anyone who is outside and advise them to remain stationary and not to touch the crane!
– Move the crane away from the danger zone.
5.5 Ram work or pulling sheet piles

Vibration can be transmitted to the supporting steel structure of the crane during ram work or when
pulling sheet piles with the crane. This vibration can cause premature fatigue of the material and
therefore cracks in the supporting steel structure.
DANGER
Important instructions for “ram work” or “pulling sheet piles”!
If the crane is used for ram work or pulling sheet piles, then the following instructions must be
followed. Failure to follow the instructions can result in damage to the crane.
The ramming equipment must not introduce vibration into the boom head!
When pulling sheet piles the maximum lifting power of the crane is limited according to the load
chart! Restricting the maximum lifting power via the crane overload protection only is prohibited!
The pull force must be additionally checked by measuring.
538 LIEBHERR 4.08

4.12 Two hook operation 021688-08
blank page!
4.12 LIEBHERR 539

021688-08 4.12 Two hook operation
B108770
540 LIEBHERR 4.12

1 General
In 2-hook operations there is a difference between:
1.) Operations with a boom nose* on the telescopic boom
2.) Operations with a boom nose* on the lattice jib
3.) Operations with a boom extension (folding jib, auxiliary boom, luffing jib)
1.1 Operations with a boom nose* on the telescopic boom

NOTICE
Danger of damage on the hoist ropes!
When reeving in, the hoist rope 1 and hoist rope 2 must be guided through the bracket 3 on the
telescopic boom!
Guide the hoist rope 1 and hoist rope 2 through the bracket 3 on the telescopic boom.
This option is set up for rapid hoists over the boom nose, whereby the hook block reeved on the
telescopic boom can remain reeved.
No special loading tables are available for boom nose operations. The boom nose is generally run in
the telescopic boom operating mode.
DANGER
Danger of accidents because of imprecise radius and load displays.
When operating with the boom nose, the overload protection radius and load display is not
precise, because the boom nose is not taken into account in the boom geometry.
Set the operating mode of the telescopic boom to overload protection.
DANGER
Danger of accidents because of overloading the hoisting gear or the hoisting cable!
Overload protection is only achieved when the reeving on the telescopic boom is equal to, or greater
than, the reeving on the mast boom.
Set the overload protection to the smaller reeving of the two hooks.
The weight of the hook blocks (load hook), the boom nose and the lifting accessories must be added
to the load to be lifted.
Setting this to the smaller reeving of the two hooks ensures that the crane cannot be overloaded.
Enter the cable reeving that corresponds to the actual reeving on the mast nose.
4.12 LIEBHERR 541

B195475
542 LIEBHERR 4.12

1.2 Operations with a boom nose* on the lattice jib

This option is set up for rapid hoists over the boom nose, whereby the hook block reeved on the
lattice jib can remain reeved.
No special loading tables are available for boom nose operations. The boom nose is generally
extended in the lattice jib operating mode.
DANGER
Danger of accidents because of imprecise radius and load displays.
When operating with the boom nose, the overload protection radius and load display is not
precise, because the boom nose is not taken into account in the boom geometry.
Set the operating mode of the lattice jib to overload protection.
DANGER
Danger of accidents because of overloading the hoisting gear or the hoisting cable!
Overload protection is only achieved when the reeving on the lattice jib is equal to, or greater than, the
reeving on the mast boom.
Set the overload protection to the smaller reeving of the two hooks.
The weight of the hook blocks (load hook) and the lifting accessories must be added to the load to be
lifted.
Setting this to the smaller reeving of the two hooks ensures that the crane cannot be overloaded.
Enter the cable reeving that corresponds to the actual reeving on the mast nose.
4.12 LIEBHERR 543

B180647
544 LIEBHERR 4.12

1.3 Operations with a boom extension (folding jib, auxiliary boom,

luffing jib)
This option is set up for turning loads during the simultaneous operation of both sets of hoisting gear.
Note
Raising the load
The load must always be raised or lowered using the weakest component (folding jib, auxiliary
boom, luffing jib) initially at 100%
In “2-hook operations” with a boom extension (folding jib, auxiliary boom, luffing jib), the overload
protection must be set to the operating mode boom extension (folding jib, auxiliary boom, luffing
jib).
DANGER
Risk of accident by overloading the hoisting gear or hoisting cable!
The reeving on the boom must be equal to or greater than the reeving on the boom extension
(folding jib, auxiliary boom, luffing jib).
Enter the reeving that corresponds to the existing reeving on the boom extension (folding jib,
auxiliary boom, luffing jib) into the overload protection.
In this case, the maximum permissible total load corresponds to the maximum permissible load in the
corresponding loading table for operating with the boom extension (folding jib, auxiliary boom, luffing
jib).
The weight of the hook blocks (load hook) and the lifting accessories must be added to the load to be
lifted.
Note
Radius display
The radius is displayed, depending on the boom extension (folding jib, auxiliary boom, luffing jib)
entered.
The load-bearing capacity for each hook in “2-hook operations” is the permissible load in the
corresponding loading table for operating with a boom extension (folding jib, auxiliary boom, luffing
jib).
In 2-hook operations, the total load is the permissible load in the corresponding loading table for
operating with a boom extension (folding jib, auxiliary boom, luffing jib).
DANGER
Risk of accident from overloading individual components on the crane!
Lifting a load with two hooks is only permissible if done as shown in the illustrations Va. 1 and Va
2.
DANGER
Danger of accidents
If both hooks are loaded, it is forbidden to lower the boom!
In those circumstances, safety cover from the overload protection is not available.
This is why the load must always be picked up at the maximum radius.
As soon as the inner hook is pulled, the overload protection load display is wrong!
If a load is raised as shown in Va. 1, the load must first be fully lifted to 100% with the hook
furthest away.
4.12 LIEBHERR 545

028603-00 4.15 Reeving plans
B107275
546 LIEBHERR 4.15

4.15 Reeving plans 028603-00
1 Reeving plans
1.1 Assembling the auxiliary equipment*

Affix the auxiliary pulleys 1 on the intended bores.
Insert the pins 2.
Secure pins 2 with spring retainers 3.
1.2 Operation with auxiliary pulley block on pivot section*

NOTICE
Damage of auxiliary device!
If the following notes are not observed, the hook block, the hoist rope or the auxiliary pulley block can
be damaged!
For operation with auxiliary pulley block on the pivot section, do not telescope out and run only the
radii ranges, which are specified in the load chart.
Before operation with the auxiliary pulley block, the rope guard pins on the hook block must be
removed!
When the hook block is on the ground, it must be ensured that the ropes remain in the pulleys!
If the limit switch chain 4 on the hoist limit switch weight is set too short, then the hook block can run
onto the auxiliary device when the hoist rope is spooled up and damage it severely.
Do not telescope out!
On the hook block 19, remove the spring retainers 18 and pull out the rope guard pin!
Check if all ropes are in the pulleys.
Before operation with the auxiliary device, set the limit switch chain 4 on the hoist limit switch
weight to maximum length.
Check if all prerequisites have been met.
4.15 LIEBHERR 547

B191927
548 LIEBHERR 4.15

1.3 Reeving in, T-operation
1.3.1 1-pulley hook block / load hook
Reeving Rope fixed point

1x On the hook block or on the load
hook fixed point
2x On the pulley head
3x On the hook block
4.15 LIEBHERR 549

B191928
550 LIEBHERR 4.15

1.3.2 3-pulley hook block

4.15 LIEBHERR 551

B191929
552 LIEBHERR 4.15


10x On the side on the pulley head
4.15 LIEBHERR 553

B191930
554 LIEBHERR 4.15


4.15 LIEBHERR 555

B196426
556 LIEBHERR 4.15


4.15 LIEBHERR 557

B191932
558 LIEBHERR 4.15

1.4 Reeving TK / TVK / TNZK / TVNZK operation

1x On the hook block or on the load
hook fixed point
4.15 LIEBHERR 559

028383-02 4.20 Procedure for shut off of crane movements
B111215
560 LIEBHERR 4.20

4.20 Procedure for shut off of crane movements 028383-02
1 General
To operate the crane, two manually operated master switches are available.
– Master switch MS1
• Right control console
– Master switch MS2
• Left control console
To monitor the crane, depending on the crane type, up to three LICCON monitors 4 are in the
instrument panel.
– LICCON monitor, illustration 3
• User interface for entry of equipment configurations and for crane operation (crane operating
screen)
• User interface for operation with TY (only for crane types with second monitor)
• User interface for “LICCON Job planner” (only for crane types with three monitors)
Equipment in the crane cab

Crane type Manually actuated master switches LICCON monitors
LTM 1090-4.1 two (version illustration 2 ) one
LTM 1500-8.1 two (version illustration 1 ) two
LTM 11200-9.1 two version (illustration 2 ) two
LTR 1100 two (version illustration 2 ) one
LTR 11200 two (version illustration 2 ) three
In the crane operator's cab, two buttons are installed to make it possible to bring the crane from an
emergency situation after a shut off of the LICCON overload protection.
– Set up key D (Function “Exceeding the shut off limits for the LICCON overload protection”) on the
LICCON monitor with crane operating screen, illustration 3
– Button 5 “luffing in with suspended load” in the left control console
Note
The set up key D has two functions, independent of each other:
If no crane movement can be carried out due to the shut off of crane operation by the LICCON
overload protection, then by pressing the set up key D, a 100 % utilization can be exceeded and /
or an active shut off can be bypassed. The crane can thereby be controlled again in normal
operating status (utilization below 100 % and no active shut off).
When the set up key D is actuated, all erection / take down procedures can be carried out within
the erection / take down charts (assembly operation).
4.20 LIEBHERR 561

The function “Exceedance of shut off limits of the LICCON overload protection”, which is activated
with the set up key D includes the following:
– Exceedance of the maximum permissible load moment
– Bypass of the hoist top shut off
– Exceedance of limit values from load charts
– Allowance of individual, limited crane movements after LML-STOP (error message)
– Completion of crane movements outside of load charts (erection / take down procedures)
NOTICE
Multi action function “Exceedance of shut off limits of the LICCON overload protection”
If the set up key D is actuated, then it is possible to exceed several shut off limits of the LICCON
overload protection simultaneously!
The LICCON overload protection as a whole is deactivated or limited.
There is no additional protection against crane overload!
When the set up key D is actuated, it must be taken into account that the LICCON overload
protection as a whole is deactivated or limited.
WARNING
Danger of accident due to function “Exceedance of shut off limits of the LICCON overload protection”!
If the shut off limits of the LICCON overload protection are exceeded, there is no additional protection
against crane overload!
Due to erroneous operation or deliberate misuse, the crane could collapse, the boom can break off or
The button 5 “Luffing in with suspended load” and the set up key D may only be actuated when it
is ensured that no normal operating condition (utilization below 100% and no active shut off) can
be reached without the function “Exceedance of shut off limits of the LICCON overload protection”!
Actuate the set up key D only when no normal operating condition (utilization below 100% and no
active shut off) can be reached with the button 5 “Luffing in with suspended load”!
The function “Exceedance of shut off limits of the LICCON overload protection” is only permissible
in emergencies and for assembly purposes!
The set up key D may only be actuated by persons who are aware of the effects of their acts
regarding the function “exceedance of shut off limits of the LICCON overload protection”!
The function “Exceedance of shut off limits of the LICCON overload protection” requires the
presence of an authorized person and must be performed with utmost caution!
Crane operation with activated function “Exceedance of shut off limits of the LICCON overload
protection” is prohibited!
562 LIEBHERR 4.20

WARNING
Expanded working / danger zone of the crane!
Due to the function “Exceedance of shut off limits of the LICCON overload protection” it is possible
that the working / danger zone of the crane is significantly expanded!
If these circumstances are not observed, collisions and accidents can occur!
With activated function “Exceedance of shut off limits of the LICCON overload protection” take an
expanded working / danger zone of the crane into account and monitor it!
4.20 LIEBHERR 563

B111217
564 LIEBHERR 4.20

2 Instructions for resuming crane movements for

cranes with CE mark
WARNING
Risk of accident!
If the following points are not observed, personnel can be severely injured or killed.
The crane operator bears the sole and full responsibility for the adherence to measures to be
taken in case of shut off of crane movement!
The crane operator must make sure, before crane operation, that he is using the correct
description for the current programming!
Note
Check the data tag 6 to determine if your crane has a CE mark!
The following section applies to a crane with CE mark, see data tag 6.1!
If your crane does not have a CE mark, see data tag 6.2, then you must observe the description in
section “Instructions for resuming a crane movement for cranes without CE mark”!
2.1 Overview load chart for cranes with CE mark
Axle Description
r Radius boom (Working radius)
% Utilization of the crane in percentages
Position Description
7 Lower limit angle load chart
8 Upper limit angle load chart
9 Utilization up to 110% with reduced working speed
10 Area “Load chart available”
11 Area “no load chart available”
Note
If the set up key D (LICCON monitor with crane operating screen, illustration 3) is actuated in the
area “load chart available”, then the working speed is reduced and all displays of the LICCON
overload protection remain functional!!
If the set up key D is actuated in the area “no load chart available”, then the working speed is not
reduced!
4.20 LIEBHERR 565

B111218
566 LIEBHERR 4.20

2.2 Overview of acoustic / visual warnings for cranes with CE mark

– Depending on the crane type, either a warning light 12.1 or a flashing beacon 12.2 or a
combination of flashing beacon 12.2 and warning light* 12.3 are installed.
– The acoustic warnings within the crane operator's cab are turned off by pressing the button F8 on
the LICCON monitor with crane operating screen ( illustration 3).
– The acoustic warnings outside the crane operator's cab are turned off by actuating the key
button 35 on the LICCON monitor with derrick operating screen ( illustration 4).
2.2.1 Description of acoustic / visual warnings

The case numbers from the chart “Case number key” is valid for the following charts in this chapter:
– “Acoustic / visual warnings on the LICCON monitor”
– “Warning light 12.1”
– “Flashing beacon 12.2”
Case number key

Description Case Case num-
ber
Utilization of crane from 0 % to 89 % Case 001
Utilization of crane over 100 % Case 003
Shut off of crane movements - LML Stop Case 004
Luffing in with suspended load Case 005
Participating sensor (LML) defective Case 006
Exceeding the shut off limits of the LICCON overload protection Case 010
Bypass of shut off hoist top Case 011
Bypass of shut off boom / luffing down the attachment, “load chart available” Case 016
Bypass of shut off boom / luffing down the attachment, “no load chart available” Case 018
Exceeding the shut off limits of the LICCON overload protection during erection / Case 020
take down procedures, “no load chart available”
4.20 LIEBHERR 567

B111219
568 LIEBHERR 4.20

2.2.2 Acoustic / visual warnings within the crane operator's cab
Acoustic / visual warnings on the LICCON monitor

Case num- Acoustic warning LICCON Visual warning LICCON monitor
ber monitor at utilization of crane
Short Long Long Utilization of Occurrence
sound sound sound crane
From Above always From Above LMB Appears if the set up key D
90 % 100 % 90 % 100 % Stop is actuated
Case 001 — — —
Case 002 X2 O — — —
Case 003 X2 O O — — —
Case 004 X2 O — — —
Case 005 X2 X2 O O — — —
Case 006 X2 O Cannot be bypassed5
Case 010 X2 X2 O O O
Case 011 X2 O O O O O
Case 018 X2 O O
Case 020 X2 O O
O = cannot be turned off

X2 = can be turned off immediately on the LICCON monitor key F8
cannot be bypassed5 = contact Liebherr Service
4.20 LIEBHERR 569

B111220
570 LIEBHERR 4.20

2.2.3 Acoustic / visual warnings outside the crane operator's cab
Warning light 12.1

Case Utilization of crane Acoustic warning Visual warning
Signal turntable Green Yel- Red
low
Case 001 From 0 % to 89 % O1
Case 002 From 90 % to 100 % O1
Case 003 Above 100 % X1 O1
Case 004 - O1
Case 005 From 0 % to 89 % O1
Case 005 From 90 % to 100 % O1
Case 006 - O1
Case 010 From 0 % to 89 % O1
Case 010 From 90 % to 100 % O1
Case 010 Above 100 % to 110 % O2
Case 011 Up to 110 % O2
Case 011 Above 110 % O O2
Case 016 From 0 % to 89 % O1
Case 016 From 90 % to 100 % O1
Case 016 Above 100 % to 110 % O2
Case 018 No value available O2

O1 = warning light 12.1 lights up
O2 = warning light 12.1 blinks
X1 = can be shut off by momentarily pressing the button 35 on the right control console or the right
instrument panel, effective at the earliest after five seconds
4.20 LIEBHERR 571

B111220
572 LIEBHERR 4.20

Flashing beacon 12.2

Signal turntable Red
Case 004 - O2
Case 006 - O2

O2 = flashing beacon 12.2 blinks
4.20 LIEBHERR 573

B111220
574 LIEBHERR 4.20

Warning light 12.3

low
Case 001 From 0 % to 89 % O1
Case 002 From 90 % to 100 % O1
Case 004 - O2
Case 005 From 0 % to 89 % O1
Case 005 From 90 % to 100 % O1
Case 006 - O2
Case 010 From 0 % to 89 % O1
Case 010 From 90 % to 110 % O1
Case 011 Up to 110 % O1
Case 016 From 0 % to 89 % O1
Case 016 From 90 % to 110 % O1

4.20 LIEBHERR 575

B195219
576 LIEBHERR 4.20

2.3 Shut off of crane movement

Note
If the LICCON overload protection turns the crane movement off, then the exact cause for the shut
off must be determined first.
As a first step, try to rescind the crane movement which has caused a shut off.
If it is not possible to rescind the affected crane movement, then the additional steps are described
in the respective sections.
Note
For detailed description of the individually listed icons, see Crane operating instructions, chapter
4.02.
The LICCON overload protection carries out the following shut offs if a limit value is exceeded in
crane operation:
– Shut off Luffing the telescopic boom up / down
– Shut off Luffing the attachment up / down
– Shut off Spooling the winch up / out
– Shut off hoist top
– Shut off Telescoping the telescopic boom out (limit length)
– Shut off Telescoping the telescopic boom in (limit length)
– Shut off Crane movement with danger of tipping to the rear*
– Shut off Luffing cylinder (pressure too high)
– Shut off due to error message
2.3.1 Shut off Luffing the telescopic boom up / down
In icon 13 or icon 14 (lower field) arrow 13.1 or arrow 13.2 blink and the LICCON overload protection
has shut off the crane movement.
“Luffing the telescopic boom up” ( arrow 13.1) or “Luffing the telescopic boom down” ( arrow 13.2) was
shut off because the upper / lower limit angle of the selected load chart was exceeded or fallen below.
If the double arrow 13.3 appears blinking in the icon 13 or icon 14 (lower field), then the telescopic
boom was luffed up to just before the block position of the luffing cylinder. The shut off “Boom
steep” has shut the crane movement “Luffing the telescopic boom up” off.
The arrow 13.1 blinks and the crane movement “luffing the telescopic boom up” was turned off:
Luff the telescopic boom down.
Result:
– Crane operation is possible again.
The arrow 13.2 blinks and the crane movement “luffing the telescopic boom down” was turned off:
Luff the telescopic boom up.
Result:
4.20 LIEBHERR 577

The double arrow 13.3 blinks and the crane movement “luffing the telescopic boom up” was turned
off:
Result:
2.3.2 Shut off Luffing the attachment up / down
In the icon 14 (upper field) the double arrow 14.1 or double arrow 14.2 blink and the LICCON overload
protection has shut off the crane movement.
“Luffing the attachment up” ( double arrow 14.1) or “Luffing the attachment down” ( double arrow 14.2)
was shut off because the upper / lower limit angle of the selected load chart was exceeded or fallen
below.
The double arrow 14.1 blinks and the crane movement “luffing the attachment up” was turned off:
Luff the attachment down.
Result:
The double arrow 14.2 blinks and the crane movement “luffing the attachment down” was turned off:
Luff the attachment up.
Result:
2.3.3 Shut off spooling the winch up / out
In the icon 18, the line / arrow 18.1, arrow / line 18.2 or line / arrow 18.3 blink and the LICCON
overload protection has shut off the crane movement.
“Spooling the winch out” ( line / arrow 18.1) or “spooling the winch up” ( arrow / line 18.2) was shut off
because the upper / lower limit angle of the rope for the selected winch was exceeded or fallen below.
If line / line 18.3 appears blinking in the icon 18, then the affected winch is deactivated.
The line / arrow 18.1 blinks and the crane movement “spooling the winch out” was turned off:
Spool the winch up.
Result:
The line / arrow 18.2 blinks and the crane movement “spooling the winch up” was turned off:
Spool the winch out.
Result:
578 LIEBHERR 4.20

Line / line 18.3 blinks and the winch is deactivated:

Activate the winch, see Crane operating instructions, chapter 4.02.
Result:
2.3.4 Shut off hoist top
The icon 19 and Hoist top icon 20 appear in the LICCON monitor and the LICCON overload protection
has turned off crane movement.
Spooling the hoist winch up was turned off because the hook block or the load hook has run against a
hoist limit weight during the upward movement and the affected hoist limit switch was triggered.
Note
After shut off of spooling the hoist winch up (hoist top), the crane movements “telescoping the
boom out”, “luffing the boom down”, “luffing the attachment down” and possibly additional
movements which have an effect on the length of the hoist rope are also shut off. This should
minimize the risk that the crane can be damaged due to erroneous operation.
Spool the hoist winch out.

Result:
2.3.5 Shut off Telescoping the telescopic boom out (limit length)
In the “horn” icon, illustration 1 appears an error message, an acoustic signal sounds, the LICCON
overload protection has interrupted the crane movement “Telescoping the telescopic boom out” and,
depending on crane type, the double arrow in the icon 23 additionally blinks.
The crane movement “Telescoping the telescopic boom out” was shut off because the limit length of
the selected load chart has been exceeded.
Telescope the telescopic boom in.
Result:
2.3.6 Shut off Telescoping the telescopic boom in (limit length)
4.20 LIEBHERR 579

overload protection has interrupted the crane movement “Telescoping the telescopic boom in” and,
The crane movement “Telescoping the telescopic boom in” was shut off because the limit length of
the selected load chart has been fallen below.
Telescope the telescopic boom out.
Result:
2.3.7 Shut off Crane movement with danger of tipping to the rear
Note
Applies only for cranes with support force monitoring*.
WARNING
When reaching the programmed minimum / maximum support force limits there is no automatic shut
off of crane movements!
Exception: When the two supports with the lowest forces are in boom direction, then some crane
movements which increase the “danger of tipping to the rear” significantly are turned off!
If there is a “danger of tipping to the rear”, luff the boom down carefully until the support limit
forces are again within the minimum / maximum values!
Icon 24 (depending on the crane similar as on the left or right illustration) is shown in the LICCON
monitor with blinking values in both fields 24.1 of the supports with the lowest forces, an acoustic
signal sounds and the LICCON overload protection has turned off the crane movement.
Crane movements which increase the “danger of tipping to the rear” significantly were turned off.
Luff the boom down carefully until the support limit forces are again within the minimum /
maximum values and no value in the fields 24.1 blinks any longer.
Result:
2.3.8 Shut off Luffing cylinder (pressure too high)
Note
Applies only for certain crane types with respective display in the second LICCON monitor.
580 LIEBHERR 4.20

In the icon 25 (luffing cylinder pressure) the utilization bar 25.1 reaches the 100% mark and the
LICCON overload protection has shut off the crane movement.
All further movements, which directly lead to an increase of the luffing cylinder pressure are shut off.
Lower the luffing cylinder pressure by lowering the load.
or
Initiate an alternative crane movement, which lowers the luffing cylinder pressure.
Result:
In assembly operation:
Make sure that the specifications in the erection / take down charts are observed.
Lower the luffing cylinder pressure by reducing the load, for example by getting support from an
auxiliary crane.
2.3.9 Shut off due to error message
An error message appears in the “horn” icon, illustration 1, the icon 19 appears in the LICCON
monitor and the LICCON overload protection has turned the crane movement off.
Determine existing errors with the LICCON error code from the field in illustration 1, see
Diagnostics manual.
Remedy the error.
If the error cannot be remedied:
Contact LIEBHERR Service.
Troubleshooting
The erection of the crane, for example after assembly on a new job site or with another equipment
configuration, is not possible due to an error message?
As the first step, make sure that all electrical connections have been made.
Check if all sensors or dummy plugs with integrated electric have been connected properly.
Note
If there is a defect on a participating sensor (LML), then the crane can no longer be operating in
normal operating condition. Contact Liebherr Service and fix / replace the sensor.
4.20 LIEBHERR 581

B111221
582 LIEBHERR 4.20

2.4 Shut off of crane movement: LML-STOP by LICCON overload

protection
WARNING
Risk of overload and toppling the crane!
If the shut off limits of the LICCON overload protection are exceeded without knowing the exact cause
for the shut off by the LICCON overload protection, then the crane can be overloaded and topple over!
Before activating the function “Exceedance of shut off limits of the LICCON overload
protection” determine the exact cause for the shut off!
WARNING
WARNING
4.20 LIEBHERR 583

B111221
584 LIEBHERR 4.20

WARNING
Failure of hoist gear!
If a load is lifted by luffing the boom up, after the hoist gear has been shut off by the load moment
limiter when trying to lift the load, then the hoist gear can be overloaded and fail!
This could result in serious accidents!
Actuate the button 5 “luffing in with suspended load” only if the LICCON overload protection
reports no overload on the hoist gear with freely suspended load, the load is not reduced by luffing
up and the minimum radius is not fallen below!
Note
If the set up key D is actuated in the area “load chart available”, then the working speed is
reduced!
If the set up key D is actuated in the area “no load chart available”, then the working speed is not
reduced!
There are two possibilities to exceed the shut off limits of the LICCON overload protection after
LML-STOP:
– With button 5 “luffing in with suspended load” in the left control console
– With the set up key D on the LICCON monitor with crane operating screen, see illustration 3
NOTICE
Danger of mix up!
The function “Exceedance of shut off limits of LICCON overload protection” can only be activated with
the set up key D on the LICCON monitor with crane operating screen, see illustration 3!
The key switches on the other monitors are not assigned with this function!
Do not mix up the set up key D with the other key switches!
In case of mix up: Deactivate the activated function!
4.20 LIEBHERR 585

B111222
586 LIEBHERR 4.20

2.4.1 Luffing in with suspended load

If the maximum permissible load moment is exceeded, the LICCON overload protection turns off all
crane movements that increase the load moment.
In the icon 22 (load moment display) the utilization bar 22.1 has exceeded the 100 % mark and in the
LICCON monitor appears the icon 19
This shut off limit can be exceeded by actuating the button 5 “luffing in with suspended load”.
– The standby mode on the LICCON monitor is not active.
– Either the seat contact button 29 or one of the buttons 1 of the master switches are actuated.
Note
If the load is reduced by luffing up, then the button 5 “luffing in with suspended load” is not
functioning.
For the procedure when the button 5 “luffing in with suspended load” is not functioning, see
section “Exceedance of maximum permissible load moment”.
Press the function key 5 “luffing in with suspended load” and hold it.
Result:
– The LICCON overload protection is inactive.
Luff the load in.

Result:
– If the crane reaches a normal operation status (utilization below 100 % and no active shut off) then
the icon 19 turns off, normal crane operation is possible again.
The function “luffing in with suspended load” is also deactivated:

– When the function key 5 “luffing in with suspended load” is not longer actuated
– When either the seat contact button 29 nor one of the buttons 1 of the master switches are
actuated
– If the standby mode on the LICCON monitor is active
– In case of defect of an associated sensor (LML)
– At engine stop
The function “luffing in with suspended load” is deactivated:
– The LICCON overload protection is active.
Carry out crane movements in such a way that no repeated shut off by the LICCON overload
protection occurs.
4.20 LIEBHERR 587

B111223
588 LIEBHERR 4.20

2.4.2 Exceedance of the maximum permissible load moment

This shut off can be exceeded by the configuration button D in the “right touching” position.
Note
In emergency situations, the function “Exceedance of shut off limits of the LICCON overload
protection” can be activated with the set up key D and the maximum permissible load moment can
be exceeded by 10% to maximum 110 %.
The set up key D on the LICCON monitor has two positions:

– Operating position (not pressed): Crane is in normal operation.
– Position to right (touching): The maximum permissible load moment (100%) can be exceeded, the
assembly icon 30 in the LICCON monitor blinks.
– With the button 5 “Luffing in with suspended load” no normal operating condition (utilization below
100% and no active shut off) can be reached.
– The master switches and the set up key D are not actuated.
– Radio operation* is not active.
– The utilization of 110 % has not been reached and a load chart is available.
Turn the set up key D to the right (touching).
Result:
– The assembly icon 30 in the LICCON monitor blinks.
– The working speed in the area “load chart available” is reduced for all functions.
Troubleshooting
When it is not possible to exceed the maximum permissible load moment by actuating the set up
key D?
4.20 LIEBHERR 589

B111223
590 LIEBHERR 4.20

Initiate crane movements which directly lead to a normal operating status (utilization below 100 %
and no active shut off).
Result:
– If a crane reaches a normal operation status (utilization below 100 % and no active shut off), then
the function “exceedance of shut off limits of the LICCON overload protection” shuts off, the
assembly icon 30 and icon 19 in the LICCON monitor turn off.
In addition, the function “exceedance of shut off limits of LICCON overload protection” turns off:
– If the set up key D is pressed again.
– If all master switches are in neutral position for 10 seconds (with load chart available)
actuated
– If radio operation* is activated
– At engine stop
– During shut off transition hoist top clear / not clear
– During transition boom not steep / steep
– During transition lower limit angle clear / not clear
– During transition upper limit angle clear / not clear
– In case of defect of an associated sensor (LML)
– When the maximum value Test point 1 (value F1) is reached
– When a utilization of 100% is reached
Note
The function “exceedance of shut off limits of the LICCON overload protection” is only turned off
when the assembly icon 30 in the LICCON monitor turns off.
If the function “exceedance of shut off limits of the LICCON overload protection” does not turn off
after pressing the set up key D once, then press the set up key D again until the assembly
icon 30 in the LICCON monitor turns off.
The function “exceedance of shut off limits of the LICCON overload protection” has / was shut off:
– The assembly icon 30 in the LICCON monitor turns off.
– The working speed is reduced until all master switches are in zero position at the same time.
Make sure that the assembly icon 30 does no longer appear in the LICCON monitor.
protection occurs.
4.20 LIEBHERR 591

B111224
592 LIEBHERR 4.20

2.5 Bypass of the hoist top shut off

WARNING
Improper use of the function “bypass of hoist top shut off”!
The function “bypass of hoist top shut off” may never be used to increase the lifting height during
crane operation!
WARNING
Property damage and falling load!
If the function “bypass of hoist top shut off” is activated, there is the danger that the hook block or the
load hook is pulled against the pulley head!
This danger exists especially when the hoist winch is continued to be spooled up and for crane
movements which have an influence on the hoist rope, for example telescoping or luffing the boom,
the attachment or the derrick boom!
Property damage and falling load can result!
The function “bypass of hoist top shut off” may only be carried out by an authorized person, along
with a guide. The guide must be in direct contact with the crane operator and must continually
monitor the distance between the hook block / load hook and the boom head!
Carry out all crane movements with utmost caution!
Note
The activation of the function “bypass of hoist top shut off” is only possible if the hoist limit switch
was touched and the hoist top shut off has occurred.
If the hoist limit switch is triggered when the set up key D is actuated (function “exceedance of
shut off limits of the LICCON overload protection” is active, the assembly icon 30 or the assembly
icon 31 blink), then a hoist top shut off occurs and the function “exceedance of shut off limits of the
LICCON overload protection” is deactivated.
For assembly purposes or in emergency cases, if the activation of the function “bypass of hoist top
shut off” and activation of the function “Exceedance of shut off limits of the LICCON overload
protection” is necessary, then the set up key D must be actuated until the icon 21 and assembly
icon 30 or assembly icon 31 (assembly operation) appear.

– A hoist top shut off has occurred, the hoist top icon 20 appears in the LICCON monitor.
– The master switches are not deflected.
– The radio operation* is not active.
4.20 LIEBHERR 593

B111224
594 LIEBHERR 4.20


Result:
– The assembly icon 30 or the assembly icon 31 (assembly operation) in the LICCON monitor blink.
– The Hoist top icon 20 in the LICCON monitor changes to the icon 21.
– The working speed is reduced for all functions (if load chart is available).
– All hoist limit switches are bypassed (also two hook operation).
Carry out a crane movement with bypassed hoist limit switches with upmost caution and by taking
the safety guidelines into account.
The function “bypass of the hoist top shut off” turns off:
– If the set up key D is pressed again
– When no master switch is deflected for 10 seconds
actuated
– If there is no longer a shut off of a hoist limit switch
– If the stand by mode on the LICCON monitor is active
– If the radio operation* is active
– At engine stop
The function “bypass of the hoist top shut off” has / was turned off:
– The assembly icon 30 or the assembly icon 31 (assembly operation) in the LICCON monitor turn
off.
– The icon 21 on the LICCON monitor turns off.
Make sure that the assembly icon 30 or the assembly icon 31 (assembly operation) as well as the
icon 21 no longer appear in the LICCON monitor.
Carry out the crane movements in such a way that no repeated hoist top shut off occurs.
4.20 LIEBHERR 595

B111233
596 LIEBHERR 4.20

2.6 Bypass of shut off luffing the telescopic boom / attachment down
WARNING
Increased danger of accidents due to bypass of shut off luffing the telescopic boom / attachment
down!
When the shut off luffing the telescopic boom / attachment down is bypassed, then the LICCON
overload protection as a whole is deactivated or limited.
When the shut off luffing the telescopic boom / attachment down is bypassed and the telescopic boom
and / or the attachment is further luffed down, then there is no load chart available any longer!
Crane operation with bypassed shut off luffing the telescopic boom / attachment down is prohibited,
since severe accidents can result!
Activate the bypass of the shut off luffing the telescopic boom / attachment down only in
emergency cases or for erection / take down procedures with erection / take down charts!

– In icon 13 or icon 14 the arrow 13.2 or double arrow 14.2 blink and the LICCON overload
Result:
– The function “exceedance of shut off limits of the LICCON overload protection” is activated and
has bypassed the shut off luffing the telescopic boom / attachment down.
Note
When leaving the area “load chart available”, the assembly icon 30 turns off and the assembly
icon 31 appears.
The bypass of the shut off luffing the telescopic boom / attachment down turns off:
actuated
– When an area with existing load chart is reached
– At engine stop
The bypass of the shut off luffing the telescopic boom / attachment down has / was turned off:
– The assembly icon 31 or the assembly icon 30 in the LICCON monitor turns off.
Make sure that the assembly icon 30 or the assembly icon 31 no longer appear in the LICCON
monitor.
4.20 LIEBHERR 597

B111225
598 LIEBHERR 4.20

2.7 Exceeding the shut off limits of the LICCON overload protection
during erection / take down procedures (assembly operation)
Note
If the crane is in the area “no load chart available”, there is a shut off of crane operation by the
LICCON overload protection and the icon 19 appears in the LICCON monitor.
By an actuated set up key D, the function “exceedance of shut off limits of the LICCON overload
protection” can be activated, all erection / take down procedures can be carried out within the
erection / take down charts, for which no load charts are available.
WARNING
Danger of accident during erection / take down procedures!
If the erection / take down charts are not observed, the crane could collapse, the boom can break off
or the crane can topple over!
The erection / take down charts must be observed!
Press the set up key D only when the configuration status has been entered correctly in the
LICCON computer system and matches the actual situation!

– The erection / take down charts are adhered to.
– The configuration status has been entered correctly into the LICCON computer system.
Result:
– The assembly icon 30 appears in the area “load chart available”.
– The assembly icon 31 appears in the area “no load chart available”.
– The erection / take down procedures can be carried out.
The function “exceedance of shut off limits of the LICCON overload protection” turns off:
– When all master switches are for 10 seconds after actuation of the set up key D in neutral position
(with “load chart available”)
actuated
– At engine stop
– When an area with existing load chart is reached (erection procedure)
After completion of the erection / take down procedures, make sure that the assembly icon 30 or
the assembly icon 31 no longer appear in the LICCON monitor.
4.20 LIEBHERR 599

B111226
600 LIEBHERR 4.20

3 Instructions for resuming crane movements for

cranes without CE mark
WARNING
Risk of accident!
If the following points are not observed, personnel can be severely injured or killed.
The crane operator bears the sole and full responsibility for the adherence to measures to be
taken in case of shut off of crane movement!
The crane operator must make sure, before crane operation, that he is using the correct
description for the current programming!
Note
Check the data tag 6 to determine if your crane has a CE mark!
The following section applies to a crane without CE mark, see data tag 6.2!
If your crane does have a CE mark, see data tag 6.1, then you must observe the description in
section “Instructions for resuming a crane movement for cranes with CE mark”!
3.1 Overview load chart for cranes without CE mark
Axle Description
r Radius boom (Working radius)
% Utilization of the crane in percentages
Position Description
7 Lower limit angle
8 Upper limit angle
9 Area “Exceeding the overload protection”
10 Area “Load chart available”
11 Area “no load chart available”
Note
If the set up key D (LICCON monitor with crane operating screen, illustration 3) is actuated, the
working speed is not reduced!
4.20 LIEBHERR 601

B111218
602 LIEBHERR 4.20

3.2 Overview of acoustic / visual warnings for cranes without CE mark

– Depending on the crane type, either a warning light 12.1 or a flashing beacon 12.2 or a
combination of flashing beacon 12.2 and warning light* 12.3 are installed.
– The acoustic warnings within the crane operator's cab are turned off by pressing the button F8 on
the LICCON monitor with crane operating screen ( illustration 3).
– The acoustic warnings outside the crane operator's cab are turned off by actuating the key
button 35 on the LICCON monitor with derrick operating screen ( illustration 4).
3.2.1 Description of acoustic / visual warnings

The case numbers from the chart “Case number key” is valid for the following charts in this chapter:
– “Acoustic / visual warnings on the LICCON monitor”
– “Flashing beacon 12.2”
Case number key

Description Case Case num-
ber
Utilization of crane over 100 % Case 003
Shut off of crane movements - LML Stop Case 004
Luffing in with suspended load Case 005
Participating sensor (LML) defective Case 006
Exceeding the shut off limits of the LICCON overload protection Case 010
Bypass of shut off hoist top Case 011
Bypass of shut off boom / luffing down the attachment, “load chart available” Case 016
Bypass of shut off boom / luffing down the attachment, “no load chart available” Case 018
Exceeding the shut off limits of the LICCON overload protection during erection / Case 020
take down procedures, “no load chart available”
4.20 LIEBHERR 603

B111219
604 LIEBHERR 4.20

3.2.2 Acoustic / visual warnings within the crane operator's cab
Acoustic / visual warnings on the LICCON monitor

Case num- Acoustic warning LICCON Visual warning LICCON monitor
ber monitor at utilization of crane
Short Long Long Utilization of Occurrence
sound sound sound crane
From Above always From Above LMB Appears if the set up key D
90 % 100 % 90 % 100 % Stop is actuated
Case 001 — — —
Case 002 X2 O — — —
Case 003 X2 O O — — —
Case 004 X2 O — — —
Case 005 X2 X2 O O — — —
Case 006 X2 O O
Case 011 X2 O O O O O
Case 018 X2 O O
Case 020 X2 O O

X2 = can be turned off immediately on the LICCON monitor key F8
4.20 LIEBHERR 605

B111220
606 LIEBHERR 4.20

3.2.3 Acoustic / visual warnings outside the crane operator's cab
Warning light 12.1

low
Case 001 From 0 % to 89 % O1
Case 002 From 90 % to 100 % O1
Case 004 - O1
Case 005 From 0 % to 89 % O1
Case 005 From 90 % to 100 % O1
Case 006 - O2
Case 010 From 0 % to 89 % O1
Case 010 From 90 % to 100 % O1
Case 011 From 0% to 100 % O2
Case 016 Up to 90 % O1
Case 016 Above 100 % to 110 % O1

4.20 LIEBHERR 607

B111220
608 LIEBHERR 4.20

Flashing beacon 12.2

Signal turntable Red
Case 004 - O2
Case 006 - O2

O2 = flashing beacon 12.2 blinks
4.20 LIEBHERR 609

B111220
610 LIEBHERR 4.20

Warning light 12.3

low
Case 001 From 0 % to 89 % O1
Case 002 From 90 % to 100 % O1
Case 004 - O2
Case 005 From 0 % to 89 % O1
Case 005 From 90 % to 100 % O1
Case 006 - O2
Case 010 From 0 % to 89 % O1
Case 010 From 90 % to 100 % O1
Case 011 From 0% to 100 % O1
Case 016 From 0 % to 89 % O1
Case 016 From 90 % to 100 % O1

4.20 LIEBHERR 611

B195219
612 LIEBHERR 4.20

3.3 Shut off of crane movement

Note
If the LICCON overload protection turns the crane movement off, then the exact cause for the shut
off must be determined first.
As a first step, try to rescind the crane movement which has caused a shut off.
If it is not possible to rescind the affected crane movement, then the additional steps are described
in the respective sections.
Note
For detailed description of the individually listed icons, see Crane operating instructions, chapter
4.02.
The LICCON overload protection carries out the following shut offs if a limit value is exceeded in
crane operation:
– Shut off Luffing the telescopic boom up / down
– Shut off Luffing the attachment up / down
– Shut off spooling the winch up / out
– Shut off hoist top
– Shut off Telescoping the telescopic boom out (limit length)
– Shut off Telescoping the telescopic boom in (limit length)
– Shut off Crane movement with danger of tipping to the rear*
– Shut off Luffing cylinder (pressure too high)
– Shut off due to error message
3.3.1 Shut off Luffing the telescopic boom up / down
In icon 13 or icon 14 (lower field) arrow 13.1 or arrow 13.2 blink and the LICCON overload protection
has shut off the crane movement.
“Luffing the telescopic boom up” ( arrow 13.1) or “Luffing the telescopic boom down” ( arrow 13.2) was
shut off because the upper / lower limit angle of the selected load chart was exceeded or fallen below.
If the double arrow 13.3 appears blinking in the icon 13 or icon 14 (lower field), then the telescopic
boom was luffed up to just before the block position of the luffing cylinder. The shut off “Boom
steep” has shut the crane movement “Luffing the telescopic boom up” off.
The arrow 13.1 blinks and the crane movement “luffing the telescopic boom up” was turned off:
Result:
The arrow 13.2 blinks and the crane movement “luffing the telescopic boom down” was turned off:
Luff the telescopic boom up.
Result:
4.20 LIEBHERR 613

The double arrow 13.3 blinks and the crane movement “luffing the telescopic boom up” was turned
off:
Result:
3.3.2 Shut off Luffing the attachment up / down
In the icon 14 (upper field) the double arrow 14.1 or double arrow 14.2 blink and the LICCON overload
“Luffing the attachment up” ( double arrow 14.1) or “Luffing the attachment down” ( double arrow 14.2)
was shut off because the upper / lower limit angle of the selected load chart was exceeded or fallen
below.
The double arrow 14.1 blinks and the crane movement “luffing the attachment up” was turned off:
Luff the attachment down.
Result:
The double arrow 14.2 blinks and the crane movement “luffing the attachment down” was turned off:
Luff the attachment up.
Result:
3.3.3 Shut off spooling the winch up / out
In the icon 18, the line / arrow 18.1, arrow / line 18.2 or line / arrow 18.3 blink and the LICCON
overload protection has shut off the crane movement.
“Spooling the winch out” ( line / arrow 18.1) or “spooling the winch up” ( arrow / line 18.2) was shut off
because the upper / lower limit angle of the rope for the selected winch was exceeded or fallen below.
If line / line 18.3 appears blinking in the icon 18, then the affected winch is deactivated.
The line / arrow 18.1 blinks and the crane movement “spooling the winch out” was turned off:
Spool the winch up.
Result:
The line / arrow 18.2 blinks and the crane movement “spooling the winch up” was turned off:
Spool the winch out.
Result:
614 LIEBHERR 4.20

Line / line 18.3 blinks and the winch is deactivated:

Activate the winch, see Crane operating instructions, chapter 4.02.
Result:
3.3.4 Shut off hoist top
The icon 19 and Hoist top icon 20 appear in the LICCON monitor and the LICCON overload protection
has turned off crane movement.
Spooling the hoist winch up was turned off because the hook block or the load hook has run against a
hoist limit weight during the upward movement and the affected hoist limit switch was triggered.
Note
After shut off of spooling the hoist winch up (hoist top), the crane movements “telescoping the
boom out”, “luffing the boom down”, “luffing the attachment down” and possibly additional
movements which have an effect on the length of the hoist rope are also shut off. This should
minimize the risk that the crane can be damaged due to erroneous operation.
Spool the hoist winch out.

Result:
3.3.5 Shut off Telescoping the telescopic boom out (limit length)
overload protection has interrupted the crane movement “Telescoping the telescopic boom out” and,
The crane movement “Telescoping the telescopic boom out” was shut off because the limit length of
the selected load chart has been exceeded.
Telescope the telescopic boom in.
Result:
3.3.6 Shut off Telescoping the telescopic boom in (limit length)
4.20 LIEBHERR 615

overload protection has interrupted the crane movement “Telescoping the telescopic boom in” and,
The crane movement “Telescoping the telescopic boom in” was shut off because the limit length of
the selected load chart has been fallen below.
Telescope the telescopic boom out.
Result:
3.3.7 Shut off Crane movement with danger of tipping to the rear
Note
Applies only for cranes with support force monitoring*.
WARNING
When reaching the programmed minimum / maximum support force limits there is no automatic shut
off of crane movements!
Exception: When the two supports with the lowest forces are in boom direction, then some crane
movements which increase the “danger of tipping to the rear” significantly are turned off!
If there is a “danger of tipping to the rear”, luff the boom down carefully until the support limit
forces are again within the minimum / maximum values!
Icon 24 (depending on the crane similar as on the left or right illustration) is shown in the LICCON
monitor with blinking values in both fields 24.1 of the supports with the lowest forces, an acoustic
signal sounds and the LICCON overload protection has turned off the crane movement.
Crane movements which increase the “danger of tipping to the rear” significantly were turned off.
Luff the boom down carefully until the support limit forces are again within the minimum /
maximum values and no value in the fields 24.1 blinks any longer.
Result:
3.3.8 Shut off Luffing cylinder (pressure too high)
Note
Applies only for certain crane types with respective display in the second LICCON monitor.
616 LIEBHERR 4.20

In the icon 25 (luffing cylinder pressure) the utilization bar 25.1 reaches the 100% mark and the
LICCON overload protection has shut off the crane movement.
All further movements, which directly lead to an increase of the luffing cylinder pressure are shut off.
Lower the luffing cylinder pressure by lowering the load.
or
Initiate an alternative crane movement, which lowers the luffing cylinder pressure.
Result:
In assembly operation:
Make sure that the specifications in the erection / take down charts are observed.
Lower the luffing cylinder pressure by reducing the load, for example by getting support from an
auxiliary crane.
3.3.9 Shut off due to error message
An error message appears in the “horn” icon, illustration 1, the icon 19 appears in the LICCON
monitor and the LICCON overload protection has turned the crane movement off.
WARNING
Limited warning functions
If there is a defect on a participating sensor (LML) and the crane is continued to be operated by
bypassing the sensor other otherwise, then the warning functions and the shut offs of the LICCON
overload protection are deactivated!
If there is a defect on a participating sensor (LML), then the crane may not be operated further!
Fix / replace the sensor before starting crane operation again!
Determine existing errors with the LICCON error code from the field in illustration 1, see
Diagnostics manual.
Remedy the error.
Troubleshooting
The erection of the crane, for example after assembly on a new job site or with another equipment
configuration, is not possible due to an error message?
As the first step, make sure that all electrical connections have been made.
Check if all sensors or dummy plugs with integrated electric have been connected properly.

4.20 LIEBHERR 617

B111221
618 LIEBHERR 4.20

3.4 Shut off of crane movement: LML-STOP by LICCON overload

protection
WARNING
Risk of overload and toppling the crane!
If the shut off limits of the LICCON overload protection are exceeded without knowing the exact cause
for the shut off by the LICCON overload protection, then the crane can be overloaded and topple over!
Before activating the function “Exceedance of shut off limits of the LICCON overload
protection” determine the exact cause for the shut off!
WARNING
WARNING
4.20 LIEBHERR 619

B111221
620 LIEBHERR 4.20

WARNING
Failure of hoist gear!
If a load is lifted by luffing the boom up, after the hoist gear has been shut off by the load moment
limiter when trying to lift the load, then the hoist gear can be overloaded and fail!
This could result in serious accidents!
Actuate the button 5 “luffing in with suspended load” only if the LICCON overload protection
reports no overload on the hoist gear with freely suspended load, the load is not reduced by luffing
up and the minimum radius is not fallen below!
There are two possibilities to exceed the shut off limits of the LICCON overload protection after
LML-STOP:
– With button 5 “luffing in with suspended load” in the left control console
– With the set up key D on the LICCON monitor with crane operating screen, see illustration 3
NOTICE
Danger of mix up!
The function “Exceedance of shut off limits of LICCON overload protection” can only be activated with
the set up key D on the LICCON monitor with crane operating screen, see illustration 3!
The key switches on the other monitors are not assigned with this function!
Do not mix up the set up key D with the other key switches!
In case of mix up: Deactivate the activated function!
4.20 LIEBHERR 621

B111222
622 LIEBHERR 4.20

3.4.1 Luffing in with suspended load

This shut off limit can be exceeded by actuating the button 5 “luffing in with suspended load”.
Note
If the load is reduced by luffing up, then the button 5 “luffing in with suspended load” is not
functioning.
For the procedure when the button 5 “luffing in with suspended load” is not functioning, see
section “Exceedance of maximum permissible load moment”.
Press the function key 5 “luffing in with suspended load” and hold it.
Result:
Luff the load in.

Result:
– If the crane reaches a normal operation status (utilization below 100 % and no active shut off) then
the icon 19 turns off, normal crane operation is possible again.
The function “luffing in with suspended load” is also deactivated:

– When the function key 5 “luffing in with suspended load” is not longer actuated
actuated
– At engine stop
The function “luffing in with suspended load” is deactivated:
– The LICCON overload protection is active.
protection occurs.
4.20 LIEBHERR 623

B111223
624 LIEBHERR 4.20

3.4.2 Exceedance of the maximum permissible load moment

LICCON monitor appears the icon 19.
This shut off can be exceeded by the configuration button D in the “right touching” position.
Note
In emergency situations, the function “Exceedance of shut off limits of the LICCON overload
protection” can be activated with the set up key D and the maximum permissible load moment of
100 % can be exceeded.
The set up key D on the LICCON monitor has two positions:

– Operating position (not pressed): Crane is in normal operation.
– Position to right (touching): The maximum permissible load moment (100%) can be exceeded, the
assembly icon 30 in the LICCON monitor blinks.
– With the button 5 “Luffing in with suspended load” no normal operating condition (utilization below
100% and no active shut off) can be reached.
Result:
Troubleshooting
When it is not possible to exceed the maximum permissible load moment by actuating the set up
key D?
4.20 LIEBHERR 625

B111223
626 LIEBHERR 4.20

Initiate crane movements which directly lead to a normal operating status (utilization below 100 %
and no active shut off).
Result:
– If a crane reaches a normal operation status (utilization below 100 % and no active shut off), then
the function “exceedance of shut off limits of the LICCON overload protection” shuts off, the
assembly icon 30 and icon 19 in the LICCON monitor turn off.
In addition, the function “exceedance of shut off limits of LICCON overload protection” turns off:
– If all master switches are in neutral position for 10 seconds (with load chart available)
actuated
– If radio operation* is activated
– At engine stop
– During shut off transition hoist top clear / not clear
– During transition boom not steep / steep
– During transition lower limit angle clear / not clear
– During transition upper limit angle clear / not clear
– When the maximum value Test point 1 (value F1) is reached
Note
The function “exceedance of shut off limits of the LICCON overload protection” is only turned off
when the assembly icon 30 in the LICCON monitor turns off.
If the function “exceedance of shut off limits of the LICCON overload protection” does not turn off
after pressing the set up key D once, then press the set up key D again until the assembly
icon 30 in the LICCON monitor turns off.
The exceedance of the shut off limits of the LICCON overload protection has / was shut off:
– The assembly icon 30 in the LICCON monitor turns off.
Make sure that the assembly icon 30 does no longer appear in the LICCON monitor.
protection occurs.
4.20 LIEBHERR 627

B111224
628 LIEBHERR 4.20

3.5 Bypass of the hoist top shut off

WARNING
Improper use of the function “bypass of hoist top shut off”!
The function “bypass of hoist top shut off” may never be used to increase the lifting height during
crane operation!
WARNING
Property damage and falling load!
If the function “bypass of hoist top shut off” is activated, there is the danger that the hook block or the
load hook is pulled against the pulley head!
This danger exists especially when the hoist winch is continued to be spooled up and for crane
movements which have an influence on the hoist rope, for example telescoping or luffing the boom,
the attachment or the derrick boom!
Property damage and falling load can result!
The function “bypass of hoist top shut off” may only be carried out by an authorized person, along
with a guide. The guide must be in direct contact with the crane operator and must continually
monitor the distance between the hook block / load hook and the boom head!
Note
The activation of the function “bypass of hoist top shut off” is only possible if the hoist limit switch
was touched and the hoist top shut off has occurred.
If the hoist limit switch is triggered when the set up key D is actuated (function “exceedance of
shut off limits of the LICCON overload protection” is active, the assembly icon 30 or the assembly
icon 31 blink), then a hoist top shut off occurs and the function “exceedance of shut off limits of the
LICCON overload protection” is deactivated.
For assembly purposes or in emergency cases, if the activation of the function “bypass of hoist top
shut off” and activation of the function “Exceedance of shut off limits of the LICCON overload
protection” is necessary, then the set up key D must be actuated until the icon 21 and assembly
icon 30 or assembly icon 31 (assembly operation) appear.

– A hoist top shut off has occurred, the hoist top icon 20 appears in the LICCON monitor.
4.20 LIEBHERR 629

B111224
630 LIEBHERR 4.20


Result:
– The assembly icon 30 or the assembly icon 31 (assembly operation) in the LICCON monitor blink.
– The Hoist top icon 20 in the LICCON monitor changes to the icon 21.
– All hoist limit switches are bypassed (also two hook operation).
Carry out a crane movement with bypassed hoist limit switches with upmost caution and by taking
the safety guidelines into account.
The function “bypass of the hoist top shut off” turns off:
– if the set up key D is pressed again
actuated
– If there is no longer a shut off of a hoist limit switch
– At engine stop
The function “bypass of the hoist top shut off” has / was turned off:
– The assembly icon 30 or the assembly icon 31 (assembly operation) in the LICCON monitor turn
off.
– The icon 21 on the LICCON monitor turns off.
Make sure that the assembly icon 30 or the assembly icon 31 (assembly operation) as well as the
icon 21 no longer appear in the LICCON monitor.
Carry out the crane movements in such a way that no repeated hoist top shut off occurs.
4.20 LIEBHERR 631

B111233
632 LIEBHERR 4.20

3.6 Bypass of shut off luffing the telescopic boom / attachment down
WARNING
Increased danger of accidents due to bypass of shut off luffing the telescopic boom / attachment
down!
When the shut off luffing the telescopic boom / attachment down is bypassed, then the LICCON
overload protection as a whole is deactivated or limited.
When the shut off luffing the telescopic boom / attachment down is bypassed and the telescopic boom
and / or the attachment is further luffed down, then there is no load chart available any longer!
Crane operation with bypassed shut off luffing the telescopic boom / attachment down is prohibited,
since severe accidents can result!
Activate the bypass of the shut off luffing the telescopic boom / attachment down only in
emergency cases or for erection / take down procedures with erection / take down charts!

– In icon 13 or icon 14 the arrow 13.2 or double arrow 14.2 blink and the LICCON overload
Result:
– The function “exceedance of shut off limits of the LICCON overload protection” is activated and
has bypassed the shut off luffing the telescopic boom / attachment down.
Note
When leaving the area “load chart available”, the assembly icon 30 turns off and the assembly
icon 31 appears.
The bypass of the shut off luffing the telescopic boom / attachment down turns off:
actuated
– When an area with existing load chart is reached
– At engine stop
The bypass of the shut off luffing the telescopic boom / attachment down has / was turned off:
Make sure that the assembly icon 30 or the assembly icon 31 no longer appear in the LICCON
monitor.
4.20 LIEBHERR 633

B111225
634 LIEBHERR 4.20

3.7 Exceeding the shut off limits of the LICCON overload protection
during erection / take down procedures (assembly operation)
Note
If the crane is in the area “no load chart available”, there is a shut off of crane operation by the
LICCON overload protection and the icon 19 appears in the LICCON monitor.
By an actuated set up key D, the function “exceedance of shut off limits of the LICCON overload
protection” can be activated, all erection / take down procedures can be carried out within the
erection / take down charts, for which no load charts are available.
WARNING
Danger of accident during erection / take down procedures!
If the erection / take down charts are not observed, the crane could collapse, the boom can break off
or the crane can topple over!
The erection / take down charts must be observed!
Press the set up key D only when the configuration status has been entered correctly in the
LICCON computer system and matches the actual situation!

– The erection / take down charts are adhered to.
– The configuration status has been entered correctly into the LICCON computer system.
Result:
– The assembly icon 30 appears in the area “load chart available”.
– The assembly icon 31 appears in the area “no load chart available”.
– The erection / take down procedures can be carried out.
The exceedance of the shut off limits of LICCON overload protection turns off:
– When all master switches are for 10 seconds after actuation of the set up key D in neutral position
(with “load chart available”)
actuated
– At engine stop
– When an area with existing load chart is reached (erection procedure)
After completion of the erection / take down procedures, make sure that the assembly icon 30 or
the assembly icon 31 no longer appear in the LICCON monitor.
4.20 LIEBHERR 635

636 LIEBHERR
5.00 Equipment
LIEBHERR 637
028014-01 5.01 Safety technical guidelines for assembly and disassembly
B195219
638 LIEBHERR 5.01

5.01 Safety technical guidelines for assembly and disassembly 028014-01
1 Checking the retaining elements

Retaining elements are used to secure the pins in the folding jibs and lattice sections. The spring
force of the retaining elements may significantly reduce if they are mechanically damaged or distorted.
Do not re-use retaining elements if there is insufficient spring force. The pins must be secured with
correctly functioning retaining elements.
DANGER
Risk of accident if retaining element does not provide enough spring force!
It cannot be guaranteed that the pin is correctly secured if the retaining element does not provide
sufficient spring force.
Use retaining elements with sufficient spring force!
2 Rope pulleys
WARNING
Danger of crushing due to rotating rope pulleys!
Arms and legs can be crushed or severed between the rope pulley and the rope due to rotating rope
pulleys!
It is prohibited to touch the ropes or rope pulleys during operation!
Adhere to the safety distance to ropes and rotating rope pulleys!
3 Checking the ropes

The ropes must be checked by an expert before assembly and checks must be performed at regular
intervals in order to detect possible damage or wear and tear at an early stage. See Crane operating
The ropes must be removed immediately if any of the following damage is detected:
– Breakage of a strand
– Wire breaks
– Broken wire nests
– Reduction in the rope diameter by 10 % or more of the nominal size.
– Rope deformation
3.1 Placing the hoist rope

In order to guarantee safety and operating characteristics, only original Liebherr replacement parts or
parts approved by Liebherr may be used.
NOTICE
If a hoist rope is placed with worn rope pulleys, the hoist rope can be damaged!
The rope pulleys must be checked before placing the hoist rope. See Crane operating instructions,
chapter 8.01!
Replace worn or damaged rope pulleys!
5.01 LIEBHERR 639

3.1.1 Cranes with cam limit switch

The cam limit switch is calibrated in the factory to switch off when only 3 hoist rope coils are left on the
winch.
WARNING
If the following instructions are not observed, the hoist rope end attachment may be torn out causing
the load to topple.
If a new hoist rope is used, the cam limit switch must be reset!
The cam limit switch must be adjusted so that it turns off when only 3 hoist rope coils remain on
the winch!
If the hoist rope is wound up during the assembly, the hoist rope end must remain in front of the
winch and may not be pulled over the winch, otherwise the cam limit switch must be reset!
3.1.2 Cranes with winch turn sensor

The winch turn sensor is calibrated in the factory to switch off when only 4 hoist rope coils are left on
the winch. If used properly, the winch turn sensor will not need to be readjusted.
WARNING
If the following instructions are not observed, the hoist rope end attachment may be torn out causing
the load to topple.
The winch turn sensor must be set to turn off when only 4 hoist rope coils remain on the winch!
Note
Avoid the following situations otherwise the winch speed sensor will need readjusting:
Pulling the hoist rope ends under the winch by spooling up the winch!
Pulling the hoist rope from the “stationary” winch.
The winch turn sensor must also be readjusted if it is established that the “winch does not stop
spooling out” when 4 rope coils are left on the winch. This applies during operation or when
changing the hoist rope.
4 Inspection procedures
WARNING
If the control measures are not carried out before crane operation, then the crane can topple over or
be damaged!
Personnel can be killed or injured!
Crane operation with safety devices which are not functioning correctly is strictly prohibited!
Start crane operation only after all safety devices have been checked and are functioning
correctly!
Start crane operation only if the overload protection has been set according to the data in the load
chart!
Start crane operation only if the crane is properly supported and horizontally aligned!
Note
If the crane operator leaves the cab, even for a short time, the operating mode setting must be
checked and reset if necessary before resuming crane operation!
640 LIEBHERR 5.01

4.1 Control measures - mobile cranes

Perform the following checks before operating the crane:
– Check if the axle suspension is blocked.
– Check if the support pads are secured in the operating position.
– Check if the crane is sufficiently supported depending on the load case and the ground conditions.
– Check if there is adequate safety distance to excavations and embankments.
– Check if there are any live cables within the operating range of the crane.
– Ensure that the work can be carried out with minimum boom projection radius.
– Check that there are no obstacles that might hinder required crane movements.
– Check if the sliding beams are prevented from sliding by pins.
– Check if the crane is supported.
– Check if the crane is level.
– Check that the tires are not in contact with the ground.
– Check that the overload protection has been adjusted as per the information in the load chart.
– Check that the set up button is not active.
– Check the shut off of the overload protection by luffing the telescopic boom up.
– Check the shut off of the overload protection by running against the hoist limit switch.
– Check the easy movement and function of the wind speed sensor.
– Check the shut-off of the limit switches - boom “steepest position”. See Crane operating
– Check the easy movement of the pendulum for the mechanical relapse retainer over the total
swing range of the pendulum.
– On cranes with derrick boom:
• Check the shut off of the limit switches - derrick. See Crane operating instructions, chapter
8.12.
– On cranes with lattice jib:
• Check the shut off of the limit switches - lattice jib “steepest position”. See Crane operating
• Check the shut off of the limit switches - lattice jib “lowest position”. See Crane operating
• Check the shut off of the limit switches – flap in position lattice jib “steepest position”. See
Crane operating instructions, chapter 8.12.
5.01 LIEBHERR 641

4.2 Control measures - crawler cranes

Perform the following checks before operating the crane:
– Check if the crane is sufficiently supported depending on the load case and the ground conditions.
– Check if there is adequate safety distance to excavations and embankments.
– Check if there are any live cables within the operating range of the crane.
– Ensure that the work can be carried out with minimum boom projection radius.
– Check that there are no obstacles that might hinder required crane movements.
– For crawler cranes with crane support:
• Check if the support pads are secured in the operating position.
• Check if the folding beams are prevented from sliding by pins.
• Check if the crane is supported.
– Check if the crane is level.
– Check that the overload protection has been adjusted as per the information in the load chart.
– Check that the set up button is not active.
– On certain crawler cranes:
• Check that the crawler assembly key button is turned off.
– Check the shut off of the overload protection by luffing the telescopic boom up.
– Check the shut off of the overload protection by running against the hoist limit switch.
– Check the easy movement and function of the wind speed sensor.
– Check the shut-off of the limit switches - boom “steepest position”. See Crane operating
– Check the shut off of the limit switches - derrick. See Crane operating instructions, chapter 8.12.
– Check the shut off of the limit switches - lattice jib “steepest position”. See Crane operating
– Check the shut off of the limit switches - lattice jib “lowest position”. See Crane operating
– Check the shut off of the limit switches – flap in position lattice jib “steepest position”. See Crane
– Check the easy movement of the pendulum for the mechanical relapse retainer over the total
swing range of the pendulum.
5 Dangerous conditions without shut off

5.1 Block position of relapse cylinders when setting down a load
NOTICE
Damage to boom or relapse cylinder!
If the block position of the relapse cylinders is triggered by the boom or the derrick with attached,
freely suspended load, then there is a danger of damaging the boom or the relapse cylinders when
setting down the load onto the ground! By setting down the load, the crane is relieved, which causes
the boom system to move to the rear.
There is no shut off of the hoist gear down function!
Actuate the opposite direction of movement which caused the block position and eliminate the
block position!
6 Transporting components
If any components are transported on an auxiliary vehicle, then they must be properly secured. If
necessary, transport these components on supports or using a special transport device.
642 LIEBHERR 5.01

6.1 Transporting lattice sections

If the lattice sections are pushed inside each other for transportation purposes, they must each be
secured with 2 chains.
7 Pneumatic springs for assembly support of

components
Pneumatic springs are installed on various components to simplify the installation or removal of these
components.
WARNING
Danger of crushing!
Defective pneumatic springs no longer provide the supporting properties on the movable components!
Due to falling components, personnel can be killed or severely injured!
Always check pneumatic springs for external damage before actuating the corresponding
components!
Do not use components with defective pneumatic springs! Replace defective pneumatic springs!
It is strictly prohibited for personnel or objects to remain within the movement range of the
components, which are supported by the pneumatic spring!
It is prohibited for personnel or objects to remain within the danger zone of the moveable
components!
8 Manual rope winches for assembly support of

components
Manual rope winches are installed on various components to simplify the installation or removal of
these components.
WARNING
Danger of crushing!
Defective manual rope winches no longer provide the supporting action on the movable components!
Due to falling components, personnel can be killed or severely injured!
Always check manual rope winches for external and functional damage before actuating the
respective components!
Check the rope of the manual rope winch for damage!
At least two rope coils must always remain on the drum!
Do not use components with defective manual rope winches! Replace defective manual rope
winches!
It is strictly prohibited for personnel or objects to remain within the movement range of the
components, which are supported by the manual rope winch!
components!
5.01 LIEBHERR 643

9 Weights
Note
Please note:
The weight of each component is specified in the corresponding chapter of the Crane operating
instructions or stated on the tag attached to the corresponding component!
Contact the Service department at LIEBHERR-Werk Ehingen GmbH. if the weight of the
respective component is not stated on the tag or in the Crane operating instructions!
If components are pushed into one another (for example intermediate pieces) or folded together
(for example the folding jib), then the total weight is given by the sum of the individual
components!
Use an auxiliary crane with sufficient load carrying capacity!
10 Guy rods
WARNING
Unutilized guy rods on boom!
If guy rods are on the lattice sections which are not used for operation, then there is a risk of
accidents!
Guy rods can loosen up and fall down!
The load chart is invalid!
The load display of the LICCON computer system shows the incorrect value!
The weight of the boom is too large for erection!
Disassembly and remove unutilized guy rods on the transport retainers before erecting the boom!
Note
Inspection and maintenance of guy rods, see Crane operating instructions, chapter 8.15!
644 LIEBHERR 5.01

blank page!
5.01 LIEBHERR 645

B197716 Example for cranes with LICCON overload protection
646 LIEBHERR 5.01

11 Exceeding the overload protection
DANGER
Increased accident risk when exceeding the overload protection!
As section 4.2.6.3.2 of EN 13000 does not put the requirements of appendix 1 of the EC machinery
directive 89/37/EC into concrete terms, the overload protection has not been designed according to
this definition.
Proper and destined use of the crane is ensured due to the construction of the overload protection
system and observance of the information in the Crane operating instructions. All sensibly
foreseeable erroneous operations of the crane have been taken into consideration.
Impermissible crane operation with exceeded overload protection – with the aim of increasing the
maximum load-bearing capacity of the crane above the rated value in the load chart, or to extend the
designated working range of the crane – does not constitute a sensibly foreseeable erroneous
operation, rather a deliberate improper use with high risk of accident!
The possible risks and consequences of such deliberate improper use are detailed in the operating
instructions.
Such deliberate improper use can neither be prevented by means of the constructive design, nor by
means of information in the operating instructions!
Actuate the set up button D only on according to the operating instructions!
Any other use of the set up button than that described in the operating instructions is prohibited!
5.01 LIEBHERR 647

B108048
648 LIEBHERR 5.01

12 Assembly / disassembly
WARNING
Risk of fatal injury due to incorrect assembly or disassembly!
The assembly / disassembly of components may never be performed by untrained personnel.
Incorrect assembly / disassembly can result in death or severe injury!
Assembly and disassembly may only be carried out by authorized and trained expert personnel!
Note
For assembly / disassembly of individual components, also refer to the chapters relating to those
components!
Only use the auxiliary winch (installation or reeving winch) for installation and not to lift loads!
Lifting of loads with the auxiliary winch is prohibited!
Normal assembly / disassembly procedures require all separately transported components to be

transported close to the ground using appropriate auxiliary cranes and tackle and they must be safely
(correctly) connected to the crane.
WARNING
Danger of impact and crushing!
There is a risk of impact and crushing when standing in the vicinity of suspended loads moving
sideways.
During assembly / disassembly no one may be in the dangerous area around or even underneath
the suspended load before the load has been secured!
WARNING
Risk of falling!
During assembly / disassembly, inspection and maintenance work, personnel must be secured with
appropriate fall protection equipment to prevent them from falling. If this is not observed, assembly
personnel could fall and suffer life-threatening or fatal injuries.
All assembly work must be carried out using suitable aids (lifting platforms, scaffolding, ladder,
auxiliary crane, etc.)!
If work cannot be carried out on the ground or using such aids, then assembly personnel must be
secured with the personal catch system (see Crane operating instructions, chapter 2.04) to protect
against falling! The personal protective equipment must be attached in the corresponding
fastening points on the crane (see crane operating instructions chapter 2.06).
secured for assembly / disassembly, inspection and maintenance work.
Step on aids and fall protection equipment only with clean shoes!
Keep aids and fall protection equipment clean and free from snow and ice!
It is prohibited to walk on the telescopic or an auxiliary boom without suitable protective devices!
5.01 LIEBHERR 649

B197715
650 LIEBHERR 5.01

12.1 Assembly / disassembly of booms

If lattice sections are not in contact with the ground during assembly / disassembly, then they must be
supported with suitable, stable materials. Adjust the height of the support so that the lattice sections
are not in contact with the ground. Pay particular attention if the lattice sections are equipped with
rope pulleys. Otherwise the rope pulleys could be damaged.
During disassembly it must be ensured that the auxiliary crane lifts the load vertically. The crane
operator must ensure that the load bearing capacity of the auxiliary crane is sufficient to safely raise
the dismantled component at the given radius. When attaching the auxiliary crane it must be ensured
that the hook of the auxiliary crane is above the center of gravity of the disassembled component and
the fastening ropes are attached to the load.
WARNING
Angular pulling can destroy the crane or cause it to topple over.
The hook block must always be attached vertically over the center of gravity of the load to be
lifted!
WARNING
Danger of accident at assembly / disassembly of booms!
The disassembling of unsecured or unsupported booms may result in fatal injury or mutilation.
Never unpin the pins under unsecured or unsupported booms!
Never unpin the connecting pins under unsecured or unsupported booms!
Do not stand under the booms or within the complete danger zone during the pinning and
unpinning procedure of the booms!
Safely secure the pins in the bearing points as well as receptacles!
Do not lean the ladder against the component being disassembled!
WARNING
Risk of accident from distorted pins!
Angular pulling or excessive / low hoisting force of the auxiliary crane may result in distortion of the
pins.
Distorted parts can suddenly detach themselves when the pins are unpinned. This represents a fatal
injury risk to assembly personnel.
When the pins are unpinned, the “lifting force” of the crane must be adapted to the “weight” of the
parts being lifted!
Do not remove difficult to remove pins by force!
Remove the reason for the distortion!
Note
Instructions for pinning and unpinning:
Pin or unpin both pins at the same horizontal level, i.e. left and right!
Insert the lower pins from the inside to outside and unpin from the outside to inside!
Insert and unpin horizontally installable double cone pins from the outside to inside!
Insert and unpin vertically installable double cone pins from top to bottom!
5.01 LIEBHERR 651

B197718 Example for cranes with telescopic boom
652 LIEBHERR 5.01

12.2 Assembly of lattice sections for telescopic cranes
12.2.1 Assembly of lattice sections for guyed auxiliary boom with an auxiliary crane
The illustrations serve as examples. The illustrations may differ depending on the crane.
WARNING
Risk of fatal injury when assembling auxiliary booms!
If the pins are not pinned in the given sequence, then lattice sections may suddenly fold down or even
fall down. This can result in life-threatening injuries to personnel.
Pins must be pinned in the order specified!
Pin in and secure pins at both sides ( level A) at point 1, illustration 1.

Pin in and secure pins at both sides ( level B) at point 3, illustration 1.
Lift the end section with the auxiliary crane, illustration 2.
Lift the lattice sections, illustration 3.
5.01 LIEBHERR 653

654 LIEBHERR 5.01

12.2.2 Disassembly of lattice sections for guyed auxiliary boom with an auxiliary
crane
WARNING
Risk of fatal injury when disassembling auxiliary booms!
If the pins are not unpinned in the given sequence, lattice sections may suddenly fold down or even
Pins must be unpinned in the order specified!
Luff the auxiliary boom down until the end section is lightly touching the ground, illustration 1.
Release and unpin pins at both sides ( level B) at point 1, illustration 1.
Completely remove the lattice sections, illustration 2.
Release and unpin pins at both sides ( level A) at point 3, illustration 3.
5.01 LIEBHERR 655

656 LIEBHERR 5.01

12.2.3 Assembly of lattice sections on self-supporting auxiliary booms using an

auxiliary crane
WARNING

5.01 LIEBHERR 657

658 LIEBHERR 5.01

12.2.4 Disassembly of lattice sections on self-supporting auxiliary booms using an

auxiliary crane
WARNING

5.01 LIEBHERR 659

660 LIEBHERR 5.01

12.2.5 Assembly of lattice sections on self-supporting auxiliary booms without using

an auxiliary crane
WARNING
For cranes with hydraulic angle adjustment and self-supporting auxiliary boom, the assembly /
disassembly of additional lattice sections may be performed using the crane itself.
In order to do so, proceed as follows.
Assemble the lattice sections to the required length.
Luff the auxiliary boom up until the pins can be pinned at point 2, illustration 2.
5.01 LIEBHERR 661

662 LIEBHERR 5.01

12.2.6 Disassembly of lattice sections on self-supporting auxiliary booms without

using an auxiliary crane
WARNING
For cranes with hydraulic angle adjustment and self-supporting auxiliary boom, the assembly /
disassembly of additional lattice sections may be performed using the crane itself.
In order to do so, proceed as follows.
Luff the auxiliary boom down until the end section is lightly touching the ground, illustration 2.
Luff the auxiliary boom down until the lattice section to be disassembled are completely laying on
the ground, illustration 3.
Completely remove the auxiliary boom.
5.01 LIEBHERR 663

B197710 Example for cranes with lattice mast booms
664 LIEBHERR 5.01

12.3 Assembly of lattice sections for lattice mast cranes
12.3.1 Assembly of lattice sections

WARNING
Risk of fatal injury when assembling booms!

Lift the lattice sections, illustration 3.
5.01 LIEBHERR 665

666 LIEBHERR 5.01

12.3.2 Disassembly of lattice sections

WARNING
Risk of fatal injury when disassembling booms!
Luff the boom down until the end section is lightly touching the ground, illustration 1.
Completely remove the lattice sections, illustration 2.
5.01 LIEBHERR 667

668 LIEBHERR 5.01

12.3.3 Flying assembly of lattice sections

WARNING
Risk of fatal injury when assembling booms!

5.01 LIEBHERR 669

B111448 Guying the pivot section with the SA-frame
670 LIEBHERR 5.01

12.3.4 Flying disassembly of lattice sections

The flying disassembly of lattice sections can be used on:
– Derrick boom
– Main boom
Note
Before guying the pivot section, the boom is secured to prevent it from falling down!
There are various possibilities to secure the boom to prevent it from falling down!
Guying the pivot section in flying mode with the SA-frame

Place the boom on the ground, see illustration 2.
or
WARNING
Lattice section incorrectly attached!
If the fastening equipment is attached on the bitts 2 when securing the boom, then the bitts will be
overloaded! The lattice section with be damaged and the boom can fall down! Personnel can be
severely injured or killed!
If the auxiliary crane is used to secure the boom for flying disassembly:
Do not fasten the lattice section on the bitts 2, see illustration 1!
Attach the fastening equipment in the area of point P1 on both sides on the lattice section, see
detail X!
Make sure that the long fastening equipment is used, so that the angle between the cross section
of lattice section and guyed fastening equipment is at least 60°, see detail Y!
Secure the boom with the auxiliary crane, see illustration 3.
or
WARNING
Falling boom!
If the boom is not properly and securely supported from below, then the boom can fall down!
Support the boom properly and safely with suitable material!
Support the boom, see illustration 4.

Result:
– The guy rods can be disassembled.
Place down, secure and disassemble the guy rods.

Pin and secure the guy rods SA-frame on the pivot section.
Tighten the guy rods SA-frame until the boom is in horizontal position.
Result:
– Pivot section is guyed in flying mode with the SA-frame, see illustration 5.
– The lattice sections can be disassembled in flying mode.
5.01 LIEBHERR 671

B111449 Guying the pivot section with the derrick boom
672 LIEBHERR 5.01

Guying the pivot section in flying mode with the derrick boom
Place the boom on the ground, see illustration 1.
or
WARNING
Lattice section incorrectly attached!
If the fastening equipment is attached on the bitts 2 when securing the boom, then the bitts will be
overloaded! The lattice section with be damaged and the boom can fall down! Personnel can be
severely injured or killed!
If the auxiliary crane is used to secure the boom for flying disassembly:
Do not fasten the lattice section on the bitts 2, see illustration 2!
Attach the fastening equipment in the area of point P1 on both sides on the lattice section, see
detail X!
Make sure that the long fastening equipment is used, so that the angle between the cross section
of lattice section and guyed fastening equipment is at least 60°, see detail Y!
Secure the boom with the auxiliary crane, see illustration 3.
or
WARNING
Falling boom!
If the boom is not properly supported from below, then the boom can fall down!
Support the boom properly and safely with suitable material!
Support the boom, see illustration 4.

Result:
– The guy rods can be disassembled.
Place down, secure and disassemble the guy rods.

Pin and secure the pulley block on the pivot section.
Tighten the control rope until the boom is in horizontal position.
Result:
– Pivot section is guyed in flying mode with the SA-frame, see illustration 5.
– The lattice sections can be disassembled in flying mode.
5.01 LIEBHERR 673

674 LIEBHERR 5.01

Unpinning the lattice components
WARNING
Risk of fatal injury when disassembling booms!

5.01 LIEBHERR 675

B111000 Example for cranes with LICCON overload protection
676 LIEBHERR 5.01

12.4 Bypassing during crawler assembly

Note
The crawler assembly key button is only installed on certain cranes.

– The set up button is pressed.
– The assembly icon on the LICCON monitor lights up.
WARNING
High risk of injury in case of actuated crawler assembly key button!
Operating the crawler assembly key button bypasses the overload protection! No shut off at overload
will occur in assembly mode or in crane operations!
In the event of deliberate misuse, the crane can topple over!
Personnel can be killed!
The crawler assembly key button may only be actuated for assembly tasks!
All other usage of the crawler assembly key button other than as described in the operating
instructions is prohibited!
Operating the crane with the crawler assembly key button enabled is strictly prohibited!
Actuate the crawler assembly key button.
Result:
– The indicator light in the button lights up.
To turn the crawler assembly key button off:

Turn off the crawler assembly key button by pressing the button.
Result:
– The indicator light in the button turns off.
12.5 Assembling / disassembly of hydraulic lines

When hydraulic lines are connected and disconnected with quick-release couplings, make ensure that
the coupling procedure is being performed correctly.
WARNING
Risk of accident due to loss of pressure or leakage!
Incorrectly coupled or self-loosening quick-release couplings (particularly return lines) can result in
serious injury due to component failure!
Check the quick-release couplings after installation for correct connection.
5.01 LIEBHERR 677

Release the pressure in the hydraulic system before connecting and disconnecting. Turn the
engine off and wait for short time.
Assemble coupling components (sleeve and connector) and screw together using hand-tightened
nut.
Tighten hydraulic coupling by hand. Rotate hand-tightened nut until it reaches a tangible, fixed
stop position.
13 Erection / take down

WARNING
Due to an unforeseen occurrence, for example: sudden strong wind or storm, dangers operating
situations can occur, up to toppling the crane!
The boom must be able to be placed down at any time with its current equipment!
The required counterweight must always be in direct vicinity of the crane!
The crane operator must ensure that the required counterweight is carried along when driving the
crane with the equipment in place and that the boom can be placed down at any time!
WARNING
Incorrectly assembled or non-operational limit switches and falling parts (pins, spring retainers, ice
etc.) can cause accidents!
13.1 Erection / take down for mobile cranes

– The crane is properly supported.
– The crane is aligned in horizontal direction.
– The counterweight has been installed to the turntable according to the load chart.
– The boom has been installed according to the load chart specifications and the Operating
instructions.
– All limit switches have been correctly assembled and are fully functional.
– All pin connections have been secured.
– The hoist rope has been correctly placed in the rope pulleys and prevented from jumping out with
the rope retaining pins.
– No personnel is within the danger zone.
– There are no loose parts on the boom or the auxiliary boom.
– In winter, the telescopic boom, the auxiliary boom and their associated components (limit
switches, cable drum, flashing beacon, wind speed sensor etc.) must be kept free of ice and snow.
678 LIEBHERR 5.01

13.2 Erection / take down for crawler cranes

– The crane is aligned in horizontal direction.
– The central ballast has been attached according to the load chart.
– The counterweight is stacked on the suspended ballast or on the ballast trailer according to the
load chart.
– The boom has been installed according to the load chart specifications and the Operating
instructions.
– The hoist rope has been correctly placed in the rope pulleys and prevented from jumping out with
the rope retaining pins.
– No personnel is within the danger zone.
– There are no loose parts on the boom or the auxiliary boom.
– In winter, the boom, the auxiliary boom and their associated components (limit switches, cable
drum, flashing beacon, wind speed sensor etc.) must be kept free of ice and snow.
13.3 Checking the prerequisites

Check if all prerequisites have been met.
5.01 LIEBHERR 679

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1 General
This crane may be equipped with a hydraulic or mechanical folding jib. The folding jib with
“mechanical angle adjustment” may be assembled as a straight (0 °) extension or below an angle of
22.5 ° or 45 ° to the telescopic boom. The folding jib with “hydraulic angle adjustment” may be luffed
under load from 0 ° to 45 °. The folding jib is folded onto the telescopic boom and mechanically
secured for on road travel.
DANGER
Danger of accident when moving with folding jib!
Before being driven on roads, the folding jib must be put into the transportation position and
mechanically secured.
Make sure that the folding jib is properly secured before moving the crane on public roads.
1.1 Folding jib versions

The following folding jib variations are possible:
– Single folding jib with “mechanical angle adjustment”
– Single folding jib with “hydraulic angle adjustment”
– Double folding jib with “mechanical angle adjustment”
– Double folding jib with “hydraulic angle adjustment”
– 3-piece folding jib with “mechanical angle adjustment”
– 3-piece folding jib with “hydraulic angle adjustment”
– 4-piece folding jib with “mechanical angle adjustment”
– 4-piece folding jib with “hydraulic angle adjustment”
1.1.1 Single folding jib, see illustration 1
Position Description Length

1 Adapter 1.5 m
2 Reduction piece 7.05 m
6 Pivot section 3.65 m
Length of single folding jib 12.2 m
1.1.2 Double folding jib, see illustration 2

1 Adapter 1.5 m
3 End section 9.3 m
Length of double folding jib 22.0 m
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1.1.3 3-piece folding jib, see illustration 3

1 Adapter 1.5 m
3 End section 9.3 m
4 Folding jib extension 7m
Length of 3-piece folding jib 29 m
1.1.4 4-piece folding jib, see illustration 4

1 Adapter 1.5 m
3 End section 9.3 m
Length of 4-piece folding jib 36 m
5.02 LIEBHERR 683

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1.2 Fastening points “folding jib complete”

With fastening points “folding jib complete” the end section, if also carried along, must be folded and
locked.
1.2.1 General
The folding jib has various different fastening eyes for the different methods of transporting the folding
jib. The transportation methods vary in terms of single or double folding jib and / or “mechanical angle
adjustment” or “hydraulic angle adjustment”.
The appropriate fastening eyes are marked with tags.
DANGER
Danger of accident due to incorrect attachment!
Life-threatening situations can arise if the folding jib is improperly or incorrectly attached.
Attach the folding jib according to the fastening points shown on the signs!
CAUTION
Damage of fastening points!
If the fastening equipment is too short, then the fastening points on the folding jibs can be damaged!
To attach the folding jibs, fastening equipment with a strand length of at least 2000 mm each must
be used!

Single folding jib with “mechanical angle adjustment”.
Description Abbreviation Weight

Mechanical MECH
Single folding jib EKS 2.0 t

Single folding jib with “hydraulic angle adjustment”.

Hydraulic HYDR
Single folding jib EKS 2.0 t
5.02 LIEBHERR 685

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5.02 Folding jib - TK 027719-01

Double folding jib with “mechanical angle adjustment”

Mechanical MECH
Double folding jib DKS 2.6 t

Double folding jib with “hydraulic angle adjustment”

Hydraulic HYDR
Double folding jib DKS 2.6 t
5.02 LIEBHERR 687

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5.02 Folding jib - TK 027719-01
1.3 Fastening points “separated folding jib”

The folding jib has various fastening eyes for attaching and removing the 3 or 4-piece folding jib.
The appropriate fastening eyes are marked with tags.

Reduction piece R 0.7 t

Reduction piece with end R+K 1.3 t
section
1.3.3 Folding jib extension, see illustration 11

Folding jib extension KV 0.7 t
5.02 LIEBHERR 689

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2 Assembling the folding jib

For Tele operation, the swing cylinder 10 can be folded up, if necessary.
2.1 General
DANGER
As a result of improperly mounted, damaged or non-existing catch bars 40 on the telescopic boom
pivot section, the folding jib – due to an assembly error – can fall down and cause fatal injuries.
Before folding jib assembly, make sure that the catch bar 40 is properly mounted on the telescopic
boom pivot section and that it is not damaged.
The catch bar 40 is a mechanical safety device. For that reason, it is prohibited to change the
catch bar 40 in any way.
Standing under the folding jib during the swing procedure is prohibited!
Standing in the swing area as well as in the folding area of the folding jib is prohibited!
The folding jib must be secured by an auxiliary rope during the swinging process!
DANGER
Risk of falling!
During assembly and disassembly, personnel must be secured with appropriate aids to prevent them
from falling. If this is not observed, assembly personnel could fall and suffer life-threatening injuries.
All assembly work from a height of 2 m must normally be carried out using suitable aids (lifting
platforms, scaffolding, ladders, auxiliary crane etc.)! The height above which assembly /
disassembly work must be carried out with aids depends on national regulations. The national
regulations must be adhered to!
If work cannot be carried out using these aids or from the ground, the assembly personnel must
be protected from falling using suitable means (such as safety harnesses)!
Do not walk on the telescopic boom or folding jib!

– The folding jib has been attached for transport on the telescopic boom pivot section.
– The telescopic boom has been luffed to the rear or the side in the 0° position.
DANGER
Danger of accident from involuntary swinging out of the folding jib when it is unpinned!
If the telescopic boom is not in the 0° position, a risk of accident exists due to involuntary swinging out
of the folding jib when it is unpinned.
Move the telescopic boom to 0° position.
5.02 LIEBHERR 691

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2.2 Reeving out the hoist rope on the telescopic boom head
In order to speed up subsequent reeving in of the hoist rope after assembling the folding jib, the hook
block can be set down at a distance from the crane approximating to the subsequent distance of the
telescoped in telescopic boom with assembled folding jib.
Telescope the telescopic boom out to the respective length.
Place the hook block on the ground.
Disengage the hoist rope on the rope fixed point.
Disassemble the hoist limit switch weight and the chain for safety reasons.
Note
The hoist limit switch must be pulled mechanically and the operating rope must be attached to the
telescopic boom head using the snap-hook when operating the folding jib.
The telescopic boom may remain reeved in, if the hoist rope of winch 2 is used for the folding jib
operation.
Remove the rope retaining pipes on the pulley head and on the back pulley.
Telescope the telescopic boom in again completely.
2.3 Important check before swinging out the hydraulic folding jibs
(TNZK operation)
DANGER
Danger of fatal injury if the folding jib involuntarily folds down!
When using hydraulic folding jibs (TNZK operation), before swinging the folding jib out, check if a
pressure of 60 bar is shown on the pressure gauge 44. If the pressure on the pressure gauge 44 is
too low, fatal accidents can occur if the folding jib folds down by itself!
It is expressly prohibited to swing out the folding jib with less than 60 bar on the pressure
gauge 44.
The restrictor 45 may only be operated during maintenance operations.

If the pressure gauge 44 shows low pressure:
Connect hydraulic line.
Luff the folding jib up until a pressure of at least 60 bar is shown on the pressure gauge 44.
2.4 Assembly of the single folding jib carried on the crane

The end section 3, which is not required, remains pinned to the telescopic boom during single folding
jib operation.
DANGER
Danger of fatal injuries due to toppling end section!
During operation with the single folding jib, the end section 3 may not be unpinned from the telescopic
boom. Otherwise, there is a danger of accidents if the end section 3 falls down.
Do not unpin the end section 3 on the telescopic boom!
5.02 LIEBHERR 693

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2.4.1 Assembly procedure, part 1

When swinging the folding jib support 18 in and out, ensure that the spring pin 8 is unlocked with one
hand and that the folding jib support 18 is moved overhead with the other hand.
Release and unpin the spring pin 8.
Swing the folding jib support 18 out until the spring pin 8 reengages.
For a “hydraulic folding jib” (TNZK operation), the hydraulic line must be uncoupled before swinging
the folding jib out.
If a hydraulic folding jib is being carried along:
Uncouple the hydraulic line at the point E.
Attach the auxiliary rope 17 at point C.
If a double folding jib is being carried along:
Release and unpin the pin 23.
Pull the nylon rope 13 and loosen the lock between the end section 3 and the reduction piece 2.
Start the crane engine.
Press button 451 and swing out the folding jib with swing cylinder until it can be pinned at point A.
Insert the pins 9 at the top and at the bottom at point A and secure.
DANGER
Special retaining clips must be used to secure the pins 9. The use of spring pins or spring retainers on
the pins 9 is not permitted. The folding jib may only be unlocked at point D, when the pins 9 are
pinned and secured at the top and bottom at point A.
Pin and secure pins 9 at point A at top and bottom.
Swing the safety bracket 15 with assembly rod 11 to the side.

Press lever 16 with the assembly rod 11 upward and latch into the link 14.
Press button 451 and swing the folding jib with swing cylinder all the way out.
Unlock the swing cylinder 10 with assembly rod 11.
DANGER
The folding jib may topple due to an assembly error.
Swing the reduction piece 2 with the auxiliary rope 17 by 180° until it can be pinned on the top and
at the bottom at the point B.
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2.4.2 Assembly procedure, part 2
DANGER
Risk of accident!
The use of spring springs or retaining springs is prohibited on pins 20 and pins 21!
To secure the pin 20 and the pin 21, use the special retaining clips.
Pin and secure the pin 20 on the bottom at point B.
In order to pin at the top of the point B, the hydraulic / mechanical assembly aid 22 must be used.
Release the pin 24 and unpin from bore 19.
Pin and secure the assembly aid 22 to the towing bracket with pin 24.
Close the knob 26.
Extend the hydraulic cylinder of the assembly aid 22 by operating the manual pump 25 until the
bore is aligned at the opening of the folding jib and the telescopic boom.
Pin and secure the pin 21 on top on point B.
Open the knob 26.
Result:
– The hydraulic cylinder of the assembly aid 22 returns to the starting position and the pin 24 is
released.
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2.5 Assembly of the double folding jib carried on the crane
2.5.1 Reduction piece assembly, part 1

Swing the folding jib support 18 out until the spring pin 8 reengages.
For a “hydraulic folding jib” (TNZK operation), the hydraulic line must be uncoupled before swinging
the folding jib out.
Uncouple the hydraulic line at the point E.
Release and unpin pins 12 and pin into bore 40.
Press button 451 and swing out the folding jib with swing cylinder until it can be pinned at point A.
DANGER
the pins 9 is not permitted. The folding jib may only be unlocked at point D, when the pins 9 are
Swing the safety bracket 15 with assembly rod 11 to the side.

Press lever 16 with the assembly rod 11 upward and latch into the link 14.
Press button 451 and swing the folding jib with swing cylinder all the way out.
Unlock the swing cylinder 10 with assembly rod 11.
DANGER
Swing the reduction piece 2 with the auxiliary rope 17 by 180° until it can be pinned on the top and
at the bottom at the point B.
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2.5.2 Reduction piece assembly, part 2
DANGER
Risk of accident!
The use of spring springs or retaining springs is prohibited on pins 20 and pins 21!
To secure the pin 20 and the pin 21, use the special retaining clips.
In order to pin at the top of the point B, the hydraulic / mechanical assembly aid 22 must be used.
Release the pin 24 and unpin from bore 19.
Pin and secure the assembly aid 22 to the towing bracket with pin 24.
Close the knob 26.
bore is aligned at the opening of the folding jib and the telescopic boom.
Open the knob 26.
Result:
– The hydraulic cylinder of the assembly aid 22 returns to the starting position and the pin 24 is
released.
2.5.3 Assembly of end section

Remove the auxiliary rope 17 at point C and attach on the end section 3.
CAUTION
The folding jib may swing out involuntarily!
The folding jib may swing out involuntarily while releasing the lock.
In order to prevent an involuntary swinging of the folding jib:
Hold the folding jib with the auxiliary rope!
Remove the spring retainer 7 on point F.

Pull the nylon rope 13 and loosen the lock between the end section 3 and the reduction piece 2.
Swing the end section 3 forward by 180° until it can be pinned at point C.
DANGER
The use of spring springs or retaining springs is prohibited on pins 27!
Special retaining clips must be used to secure the pins 27.
Pin and secure pins 27 at top and bottom using safety clips.
Remove the auxiliary rope.
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2.6 Assembling the 3-piece folding jib

The 3-piece folding jib is a folding jib that has been extended with a folding jib extension 4.
– The folding jib is attached on the telescopic boom or on the telescopic boom extension.
– An auxiliary crane with an adequate load-bearing capacity is available.
DANGER
Risk of accident when assembling / disassembling the 3-piece folding jib!
If the following conditions are not fulfilled, people may be fatally injured during assembly /
disassembly.
People may not stand below the folding jib when pins are removed!
The pins must be pinned and unpinned in the order specified in the operating instructions!
Attach auxiliary crane so that no sloping occurs!
Attach the reduction piece 2 to auxiliary crane and tighten the fastening rope slightly.
or
Attach the reduction piece 2 with the end section 3 on the auxiliary crane and tighten the fastening
rope slightly.
DANGER
pins.
Distorted parts can suddenly fly off when the pins are unpinned.
parts being lifted!
Release and unpin the pins 50 on both sides.
Note
Before unpinning and pinning the pins X, unbolt the extension Y or on accordingly. Then secure
the pins X on both sides with spring retainers. Before driving on public roads, the
extension Y must be removed again, and the pins X must be secured on both sides with the spring
retainers.
Release the pins 51 on both sides and unpin from the outside to the inside.
Place the reduction piece 2 down.
or
Place the reduction piece 2 with the end section 3 down.
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Fasten the folding jib extension 4 to the auxiliary crane and insert into the fork heads on the pivot
section 6.
Pin the folding jib extension 4 with the pivot section 6: Pin the pins 50 on both sides from the
outside to the inside and secure.
Pin the pins 51 on both sides from the outside to the inside and secure.
Attach the reduction piece 2 to the auxiliary crane and insert into the fork heads on the folding jib
extension 4.
or
Attach the reduction piece 2 with the end section 3 on the auxiliary crane and insert into the fork
heads on the folding jib extension 4.
Pin the reduction piece 2 with the folding jib extension 4: Pin the pins 52 on both sides from the
5.02 LIEBHERR 705

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2.7 Assembling the 4-piece folding jib

The 4-piece folding jib is a folding jib that has been extended with a folding jib extension 4 and a
folding jib extension 5.
– The folding jib is attached on the telescopic boom or on the telescopic boom extension.
– An auxiliary crane with an adequate load-bearing capacity is available.
DANGER
disassembly.
Attach cables so that no sloping occurs!
or
rope slightly.
DANGER
pins.
parts being lifted!

or
Fasten the folding jib extension 5 to the auxiliary crane and insert into the fork heads on the pivot
section 6.
Pin the folding jib extension 5 with the pivot section 6: Pin the pins 50 on both sides from the
Note
retainers.
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Attach folding jib extension 4 to the auxiliary crane and insert into the fork heads on the folding jib
extension 5.
Pin folding jib extension 4 with folding jib extension 5: Pin the pins 52 on both sides from the
Attach the reduction piece 2 to the auxiliary crane and insert into the fork heads on the folding jib
extension 4.
or
Attach the reduction piece 2 with the end section 3 on the auxiliary crane and insert into the fork
heads on the folding jib extension 4.
Pin the reduction piece 2 with the folding jib extension 4: Pin the pins 54 on both sides from the
5.02 LIEBHERR 709

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2.8 Assembling the separately transported folding jib on the crane
2.8.1 Assembling the separately transported folding jib for crane operating position
For description of fastening points, see section “Fastening points”.
Attach the auxiliary crane to the relevant fastening points of the folding jib.
Lift folding jib with auxiliary crane and insert into pin points of telescopic boom.
DANGER
Risk of accident!
The use of spring springs or spring retainers is prohibited on pins 9, pins 20 and pins 21!
Use the special retaining clips to secure pins 9, pins 20 and pins 21.
Pin the folding jib to telescopic boom:

Pin and secure the pin 9 on top on point A.
Pin and secure the pin 9 on the bottom at point A.
For more information concerning the double folding jib assembly, see section “Assembly of the
end section”.
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2.8.2 Assembling the separately transported folding jib for transport position
An auxiliary crane must be available for the assembly of the separate folding jib 1.
– The telescopic boom is in driving direction in 0° position.
DANGER
Danger of accident from involuntary swinging out of the folding jib when removing the fastening
equipment!
If the telescopic boom is not in 0° position, a risk of accident exists due to involuntary swinging out of
the folding jib when the fastening equipment is removed.
Attach the auxiliary crane to corresponding fastening points on folding jib, see section “Fastening
points”.
CAUTION
Risk of property damages!
If the following notes are not observed, the folding jib can move uncontrolled and as a result, damage
can occur in the area of the telescopic boom and the driver's cab.
Carry out auxiliary crane movements only with utmost care and the least possible acceleration.
The folding jib must be secured by an auxiliary rope during the assembly procedure!
Lift the folding jib with the auxiliary crane and guide it into pin points on the telescopic boom head.
DANGER
Risk of accident!
The use of spring springs or spring retainers is prohibited on the pins 9!
Pin the folding jib to telescopic boom:

Pin and secure pins 9 on top and on the bottom at point A.
DANGER
Danger of fatal injuries due to falling folding jib!
Due to improperly pinned folding jib on the telescopic boom, life threatening or even fatal injuries can
occur.
Before removing the auxiliary crane, make sure that the folding jib is pinned and secured on
point A on top and bottom.
Remove the auxiliary crane.
Note
For further procedure to fold the folding jib onto the telescopic boom or in transport position, refer
to section “Removing the folding jib”.
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3 Reeving in the hoist rope
DANGER
Risk of sliding off the folding jib!
When walking on the folding jib to reeve the hoist rope in or out, for example, there is a risk of slipping
and falling from the folding jib.
Do not walk on the folding jib!
3.1 Swinging the rope guide pulley into operating position

Swing the rope guide pulley 29 into operating position.
Pin the rope guide pulley 29 in operating position: Insert and secure pin 30.
3.2 Reeving in the hoist rope

Release and unpin the rope retaining pin 28 and rope retaining pin 31.
When operating with double folding jib, 3-piece folding jib or 4-piece folding jib:
Release and unpin the rope retaining pins 34.
Place the hoist rope over the rope guide pulley 29 and over the end pulley 32 at 12.2 m or over
the end pulley 35 at 22 m.
Reinsert the rope retaining pins and secure with linch pins.
CAUTION
If the rope retaining pin 31 is inserted during operation with the double folding jib, the 3-piece folding
jib or the 4-piece folding jib, then the slack hoist rope can scrape against the rope retaining pin 31 and
be damaged.
Do not insert the rope retaining pins 31 for double folding jib, 3-piece folding jib or 4-piece folding
jib operation!
Reeve in the load hook or hoist rope.

Attach the hoist limit switch weight.
Note
The weight of the reeved in hook block attached to the telescope boom must be removed from the
load during folding jib operations with hook blocks reeved in at the telescope boom.
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4 Changing mechanical folding jib from 0° to 22.5° or

45°
DANGER
If the following danger notes are not observed, fatal injuries can occur at assembly and retooling work
on the folding jib.
Make sure that there are no persons within the danger zone of the crane.
There are 2 ways of changing the mechanical folding jib to 22.5° or 45°:
1.) Angle assembly with hoist rope as holding cable, see illustration 12.
Only permitted for operation with single folding jib and double folding jib.
2.) Angle assembly with supported folding jib, see illustration 13.
– The folding jib is attached as a straight extension in the 0° position.
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4.1 Angle assembly with hoist rope as holding cable

WARNING
Danger of damage to the folding jib and the hoist rope!
If the telescopic boom is telescoped out or luffed down as long as the hoist rope is tightened on the
assembly fixed point, the hoist rope and the folding jib may be damaged.
Do not telescope the telescopic boom out or luff it down with the hoist rope attached to the
assembly fixed point!
Angle assembly with the hoist rope as holding cable is only permitted for operation with single
folding jibs and double folding jibs!
4.1.1 Preparatory work

Reeving out the hoist rope on the lock.
Remove the hoist limit switch weight.
For operation with double folding jib
Guide the press fitting 42 into the assembly fixed point 43.
or
For operation with the single folding jib
Tighten the hoist rope by carefully deflecting the appropriate manual control lever.
4.1.2 Angle settings

The folding jib can be operated in angles 0 °, 22.5 ° and 45 °. The relevant angle is set using the
pin 36.
DANGER
Risk of accident if folding jib “folds down” inadvertently!
If the following notes are not observed, the folding jib can “fold down” inadvertently!
The hole 35 must not be unpinned!
Do not unpin pin 36 unless the folding jib is being held by the hoist rope!
Release pin 36 and unpin from bore 33.

With angle setting of 22.5 °
Pin and secure the pin 36 in the bore 34.
or
With angle setting of 45 °
Insert pin 36 in transport retainer.
4.1.3 Positioning the folding jib

Pin and secure the pin 36 in the bore 34 or in the transport retainer.
Reel off the hoist rope by deflecting the appropriate manual control lever and raise the telescopic
boom at the same time until the lug 37 lies against the appropriate pin and the folding jib is
supported by the pin.
Release the press nipple at the assembly stabilising point.
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4.2 Angular assembly with supported folding jib
Note
The folding jib may contact the ground or must be properly supported, if necessary.
Completely lower the telescopic boom until the folding jib contacts the ground.
4.2.2 Angle settings

The folding jib can be operated in angles 0 °, 22.5 ° and 45 °. The relevant angle is set using the
pin 36.
DANGER
Only unpin the pin 36 if the folding jib is lying on the ground or on a proper support.
Release pin 36 and unpin from bore 33.

With angle setting of 22.5 °
or
With angle setting of 45 °
Insert pin 36 in transport retainer.

Pin and secure the pin 36 in the bore 34 or in the transport retainer.
Raise telescopic boom until the lug 37 is lying against the respective pins and the folding jib is
being held in position by the pins.
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5 Hydraulic connections
5.1 Establishing the hydraulic connections

A hydraulic connection to the folding jib must only be established for a hydraulic angle adjustment
(TNZK operation). Hydraulic lines cannot be incorrectly connected due to the different diameters of
the hydraulic connections.
For operation with a hydraulic folding jib:
Establish the hydraulic connections.
After operations with a hydraulic folding jib:
Protect the connections from contamination.
5.2 Assembling the hose couplings in operating or neutral position

The hydraulic supply to the folding jib is made via the hydraulic hose drum 440 on the telescopic
boom. For extended telescopic boom operation, the console 442 should be assembled in the
retainer 441 in the “rest position”.
This prevents unnecessary hydraulic hose winding and unwinding.
CAUTION
Danger of accident due to rebounding hydraulic hoses!
The hydraulic hoses are under spring tension. If the removed console 442 is released, it snaps back
against the hydraulic hose drum 440 due to the spring force. This can cause injury to assembly
personnel or damage the hydraulic hose drum 440.
Do not allow removed console 442 to snap back!
Hold the removed console 442 and then re-assemble!
5.2.1 Assembling the hose couplings in operating position (illustration 1)

Change the pipe 2 and secure with spring retainer 3, see illustration 1.
Unpin the console 442 with the hydraulic couplings from the retainer 441.
Place two hydraulic hoses 443 into the guides 444.
Insert and secure the console 442 into the retainer 445, see illustration 1.
Insert the pin 446 and secure with spring retainer 447, see illustration 1.
Secure the hydraulic hose 443 in the guides 444.
5.2.2 Assembling the hose couplings in resting position (illustration 2)

Release the hydraulic hose 443 in the guides 444.
Remove the console 442 with the hydraulic couplings from the retainer 445 on the boom head, to
do so, release and remove the pin 446, see illustration 1.
Remove two-fold hydraulic hoses 443 from the guides 444.
Insert and secure the console 442 with the hydraulic couplings in the retainer 441, see
illustration 2.
Insert the pin 446 and secure with spring retainer 447, see illustration 2.
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5.3 Removing the hydraulic hose drum

WARNING
Risk of falling!
During installation and removal of the hydraulic hose drum 440, personnel must be secured with
appropriate fall arrest aids to prevent them from falling. If this is not observed, assembly personnel
could fall and suffer life-threatening or fatal injuries!
Any work, where there is a danger of falling must be carried out with suitable aids (for example:
lifting platforms, scaffoldings, ladders, auxiliary crane)!
must secure themselves with approved fall arrest systems to avoid falling, see “chapter 2.04”!
It is prohibited to walk on the telescopic boom!
WARNING
Danger of fatal injuries due to toppling hose drum!
Due to an assembly / disassembly error, the hydraulic hose drum 440 can fall down!
It is prohibited for anyone to remain under the hydraulic hose drum 440 during assembly or
disassembly!

– The telescopic boom is luffed down, telescoped in and swung by 90° to the side or to the rear.
– The hydraulic connections of the hose couplings to the folding jib are released and the hose
couplings are installed in resting position, see section “Assembling the hose couplings in resting
position”.
– An auxiliary crane with suitable fastening equipment is available for removing the hydraulic hose
drum 440.
Attach the auxiliary crane on the suspension lug 7 of the hydraulic hose drum 440 with suitable
fastening equipment and secure, see illustration 3.
Unscrew the cross handles 8 from the pulley sections and remove the cable 9 from the pulley
sections, see illustration 3.
WARNING
Risk of burning due to hot oil!
When releasing hydraulic connections, hot oil can emerge!
When releasing hydraulic connections, it is imperative to use suitable work gloves!
Release all hydraulic connections from the telescopic boom to the hydraulic hose drum 440.
Remove all four hex head screws 4 from the retainer 5 and console 6, see illustration 4.
Lift the hydraulic hose drum 440 with the auxiliary crane and remove.
WARNING
When placing the hydraulic hose drum 440 down, limbs can be crushed!
Place the hydraulic hose drum 440 down especially carefully!
Place the hydraulic hose drum 440 on the center spoke 10 on level ground, see illustration 5.
Place the hydraulic hose drum 440 slowly on the retainer 5, see illustration 5.
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5.4 Installing the hydraulic hose drum

WARNING
Risk of falling!
During installation and removal of the hydraulic hose drum 440, personnel must be secured with
appropriate fall arrest aids to prevent them from falling. If this is not observed, assembly personnel
could fall and suffer life-threatening or fatal injuries!
Any work, where there is a danger of falling must be carried out with suitable aids (for example:
lifting platforms, scaffoldings, ladders, auxiliary crane)!
must secure themselves with approved fall arrest systems to avoid falling, see “chapter 2.04”!
It is prohibited to walk on the telescopic boom!
WARNING
Danger of fatal injuries due to toppling hose drum!
Due to an assembly / disassembly error, the hydraulic hose drum 440 can fall down!
It is prohibited for anyone to remain under the hydraulic hose drum 440 during assembly or
disassembly!

– The telescopic boom is luffed down, telescoped in and swung by 90° to the side or to the rear.
– An auxiliary crane with suitable fastening equipment is available for removing the hydraulic hose
drum 440.
Attach the auxiliary crane on the suspension lug 7 of the hydraulic hose drum 440 with suitable
fastening equipment and secure, see illustration 6.
Lift the hydraulic hose drum 440 with the auxiliary crane and affix on the telescopic boom.
WARNING
When installing the hydraulic hose drum 440 on the telescopic boom, limbs can be crushed!
Be especially careful at installation of the hydraulic hose drum 440!
Properly attach the retainer 5 on the console 6 with all four hex head screws 4 and new
self-tapping nuts, see illustration 7.
Guide the cable 9 into the pulley sections and attach the cross handles 8 tightly, see illustration 8.
Establish all hydraulic connections from the telescopic boom to the hydraulic hose drum 440.
Install the console 442 with hose couplings in operating position, if needed, see section “Installing
the hose couplings in operating position”.
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6 Electrical connections
6.1 Mechanically actuating the hoist limit switch, illustration 14

If you are working in “single hook mode” with the folding jib, the hoist limit switch -S930/-S931 that is
not required must be actuated manually.
Disassemble the hoist limit switch weight and chain.
Pull the hoist limit switch rope 20 and attach to the fixed point 22 with the shackle 21.
6.2 Electrical connections on the single folding jib
6.2.1 Single hook operation, illustration 15

Only the hoist limit switch S940 at the single folding jib is active during single hook operation.
Actuate the hoist limit switch -S930 mechanically.
If attached to the telescopic boom:
Actuate the hoist limit switch* -S931 mechanically.
Insert the cable plug -X500 into the socket -X556V.
Insert the adapter -X556 into the socket -X501.
Insert the hoist limit switch -S940 with the cable plug -X501 into the socket -X556H.
Insert the wind speed sensor* with the cable plug -X556W into the socket -X556.
Insert the flashing beacon* with the cable plug -X460 into the socket -X460Y.
Or insert the high voltage warning* with the cable plug -X486 into the socket -X486Y.
6.2.2 Two hook operation, illustration 16

During two hook operation the hoist limit switch S930 on the telescopic boom and the hoist limit
switch S940 on the single folding jib are active!
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6.3 Electrical connections on the double folding jib
6.3.1 Single hook operation, illustration 17

Only the hoist limit switch S945 on the double folding jib is active during single hook operation. The
hoist limit switch S940 on the single folding jib is unplugged.
Insert the cable plug -X505 into the socket -X501.
6.3.2 Two hook operation, illustration 18

switch S945 on the double folding jib are active! The hoist limit switch S940 on the single folding jib is
unplugged.
Insert the cable plug -X505 into the socket -X501.
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6.4 Function check

– All electrical connections have been made.
– The LICCON computer system is running.
6.4.1 Wind sensor
CAUTION
Danger of accidents due to toppling of the crane!
The wind speed can no longer be determined if a defective wind sensor is installed.
Check the function of the wind sensor every time it is installed.
Manually actuate the wind sensor.

Result:
– The icon element “Wind speed” 2.2 appears on the monitor.
6.4.2 Hoist limit switch

Actuate all active hoist limit switches manually.
Result:
– The appropriate icon element “Hoist top” appears on the monitor.
– The winch turns off.
Note
When replacing or changing the hoist limit switch, the hoist limit switch must have the correct bus
address and the correct software version in order to be detected by the bus system.
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7 Erection
7.1 Preparatory work

– The folding jib has been assembled according to the load chart and the operating instructions.
– The hoist rope has been correctly placed in the cable pulleys and is secured with the rope
retaining pins to prevent it from jumping out.
– There are no loose parts on the telescopic boom or the folding jib.
– The telescopic boom, the folding jib and its components (such as: limit switch, airplane warning
light, wind speed sensor) must be free of snow and ice in winter.
DANGER
Risk of accident!
Incorrectly installed or non-functioning limits switches as well as falling parts (such as: pins, cotter
pins, ice) can cause accidents!
Assemble all limit switches, pins and spring pins properly.
Check if all preconditions have been met.
7.2 Erection procedure

DANGER
The radii specified in the load chart may not be exceeded or fallen below, even if there is no load on
the hook! If this regulation is not observed, the crane can topple over.
Compare and check the settings on the LICCON computer system with the actual configuration
status!
Adjustment of the LICCON overload protection, refer to chapter 4.02.

Set and confirm the LICCON overload protection according to the required set up configuration.
Luff the telescopic boom with installed folding jib up until the LICCON signals the release.
Telescope the telescopic boom out to values specified in load chart.
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8 Adjusting the folding jib angle of the hydraulic

folding jib
The adjusting range of the folding jib lies between 0 ° and 45 ° in relation to the telescopic boom. It is
possible to luff the hydraulically adjustable folding jib under load.
DANGER
The crane may topple if the maximum load is exceeded.
The load charts for the hydraulically adjustable folding jib are only valid for angles of 0 °,
22.5 ° and 45 °!
For adjustment angles between the nominal angles of 0°, 22.5° and 45°, the LICCON computer
system will report and display the maximum load on the LICCON monitor.
Ensure that the following preconditions are fulfilled:

– All hydraulic connections have been made.
– The engine is running.
– Operating mode TNZK has been set and confirmed on the LICCON computer system.
8.1 Angle display for folding jib

The folding jib angle 50 is shown on the LICCON monitor as the relative angle between the telescopic
boom pulley head and the folding jib.
8.2 Luffing with “hydraulic angle adjustment”

– the switch 430 is set to position right “luff folding jib”
If the folding jib is to be luffed down:
Deflect the master switch 420 to the right in direction X+.
Result:
– The hydraulic folding jib is luffed down.
If the folding jib must be luffed up:

Deflect the master switch 420 to the left in direction X-.
Result:
– The hydraulic folding jib is luffed up.
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8.3 Telescoping
– The folding jib is at a nominal angle of 0° or 22.5° or 45°.
Note
Telescoping is only possible at a nominal angle of folding jib of 0° or 22.5° or 45°!
In intermediate positions between the nominal angles of the folding jib, telescoping is not possible!
If the angle changes by approx. +/-2° to the nominal angle during telescoping, then telescoping is
stopped. In this case, the crane operator must reset the folding jib to the nominal angle to be able
to continue telescoping.
Telescope the telescopic boom as described in chapter 4.05.
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9 Changing the mechanical folding jib from 22.5° or

45° to 0°
DANGER
If the following danger notes are not observed, fatal injuries can occur at assembly and retooling work
on the folding jib.
Make sure that there are no persons within the danger zone of the crane.
There are 2 ways of changing the mechanical folding jib from 22.5 °/45 ° to 0 °:
1.) Change over with hoist rope as holding cable, see illustration 12.
Only permitted for operation with single folding jib and double folding jib.
2.) Change over with supported folding jib, see illustration 13
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9.1 Change over with the hoist rope as holding cable
WARNING
If the telescopic boom is telescoped out or luffed down as long as the hoist rope is tightened on the
assembly fixed point, the hoist rope and the folding jib may be damaged.
Do not telescope the telescopic boom out or luff it down with the hoist rope attached to the
assembly fixed point!
Change over with the hoist rope as holding cable is only permitted for operations with single
folding jibs and dual folding jibs!
Lower the telescopic boom until the hook block can be reeved out on the end section of the folding
jib.
Reeve out the hoist rope on the hook block.
Remove the hoist limit switch weight.
For operation with double folding jib
or
For operation with the single folding jib
Tighten the hoist rope by carefully deflecting the appropriate manual control lever.
WARNING
As soon as the folding jib has reached the 0 ° stop, the “lifting” and “luffing” movement must be
stopped immediately.
Luff the telescopic boom down and simultaneously spool up the hoist rope so that the folding jib is
always kept at the same height of approx. 1.0 m - 1.5 m above the ground until the 0 ° position
(stop on pull bracket) has been reached.
DANGER
Do not unpin pin 36 unless the folding jib is being held by the hoist rope!
Release the pin 36 and unpin from bore 34 or remove from the transport retainer.
Disconnect the hoist rope on the assembly fixed point.
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9.2 Change over with supported folding jib

Lower telescopic boom until the hook block can be reeved out.
Remove the lock and hoist limit switch weight.
Completely lower the telescopic boom until the folding jib contacts the ground.
CAUTION
Risk of damage!
The contact surface must be stable and level, so that the folding jib does not push in the ground
when luffing.
The folding jib may contact the ground or must be properly supported, if necessary.
Continue to carefully lower the telescopic boom until the 0 ° position (stop at lugs) has been
reached.
DANGER
Only unpin the pin 36, if the folding jib is lying the ground or on a proper support!
Release the pin 36 and unpin from bore 34 or remove from the transport retainer.
5.02 LIEBHERR 745

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10 Unreeving the hoist rope
DANGER
Risk of falling from folding jib!
When walking on the folding jib to reeve the hoist rope in or out, there is a risk of slipping and falling
from the folding jib.
Do not walk on the folding jib!

– The hook block / load hook has been put down on the ground.
– The hoist rope is attached to the rope fixed point.
– The hoist limit switch weight and the chain have been removed.
10.1 Unpinning / pinning the rope retaining pin

Release and unpin the rope retaining pin 28 and rope retaining pin 31.
When operating with double folding jib, 3-piece folding jib or 4-piece folding jib:
Release and unpin the rope retaining pin 34.
Spool up the hoist rope.
Repin the rope retaining pin 28, rope retaining pin 31 and rope retaining pin 34 and secure with
linch pins.
10.2 Swinging the rope guide pulley into transport position

Swing the rope guide pulley 29 into transport position.
Pin the rope guide pulley 29 in transport position: Insert and secure pin 30.
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11 Removing the folding jib
11.1 General
DANGER
The folding jib may topple due to a disassembly error.
The folding jib must be secured by an auxiliary rope during the swinging process!
DANGER
Risk of falling!
from falling. If this is not observed, assembly personnel could fall and suffer life-threatening injuries.
All assembly work from a height of 2 m must normally be carried out using suitable aids (lifting
platforms, scaffolding, ladders, auxiliary crane etc.)! The height above which assembly /
disassembly work must be carried out with aids depends on national regulations. The national
regulations must be adhered to!
Do not walk on the telescopic boom or folding jib!

– The folding jib is in the 0° position.
– The electrical / hydraulic connections at the folding jib have been released.
– The rope guide pulley has been moved from the operating position to the transport position.
DANGER
Danger of accident from involuntary swinging out of the folding jib when it is unpinned!
of the folding jib when it is unpinned.
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11.2 Preparatory work before swivelling in hydraulic folding jibs

Prior to swinging in the hydraulic folding jib*, the folding jib must be completely luffed up and held on
block for approximately 15 seconds. This causes the hydraulic reservoir to fill.
Raise folding jib and move to the block.
Result:
– The pressure gauge 44 then must show 200 to 250 bar.
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11.3 Removing the single folding jib carried on the crane, part 1
Disengage the lever 16 with the assembly rod from the link 14 and pull downward.
Swing out the folding jib support 18 until the spring pin 8 engages again.
In order to unpin at the top of the point B, the hydraulic / mechanical assembly aid 22 must be used.
Close the knob 26 on the manual pump 25.
pin 21 can be unpinned.
Release and unpin the pin 21 on top.
Open the knob 26 on the manual pump 25.
Result:
– The hydraulic cylinder of the assembly aid 22 returns to the starting position.
Unpin the pins 24 and insert into bore 19 and secure.
DANGER
When removing the pin 20, the folding jib may swing out unintentionally.
Do not lean the ladder against the folding jib!
Release the pin 20 on the bottom and unpin.
5.02 LIEBHERR 753

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11.4 Removing the single folding jib carried on the crane, part 2
DANGER
Swing the folding jib backward until the swing cylinder 10 is locked to the folding jib.
Press button 450 and swing in the folding jib with the swing cylinder until the lock 43 engages
audibly.
Check whether the lock 43 has engaged properly.
DANGER
Danger of fatal injury when unpinning the pins 9!
If the pins 9 are unpinned before the lock 43 has engaged, then the folding jib will fall down and
possibly cause fatal injury to the assembly personnel.
The pins 9 may not be unpinned until the lock 43 has engaged and the manual lever 16 has been
secured with the safety bracket 15.
Secure the manual lever 16 with the safety bracket 15.

Release the pin 9 at point A, unpin and insert into transport retainer.
Press button 450 and swing the folding jib with swing cylinder in all the way.
Result:
– When transporting the double folding jib, the reduction piece 2 is locked with the end section 3.

Insert and secure pin 23.
Unpin the spring pin 8 and swing in the folding jib support 18 until the spring pin 8 engages.
Secure the spring pin 8.
Connect the hydraulic line to the hydraulic cylinder at the point E.
Remove the auxiliary rope 17.
“Hydraulic folding jibs” have an overflow tank attached to the hydraulic cylinder. The overflow tank
must be emptied when it is full. Even when the folding jib is not carried along on the crane.
Empty the overflow tank on the hydraulic cylinder.
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11.5 Removing the double folding jib carried on the crane
11.5.1 Removing the end section

Attach the auxiliary rope 17 on the end section.
DANGER
DANGER
The pins 23 must remain pinned.
Swing in the end section 3 and then lock with the reduction piece 2.
DANGER
The end section can swing out involuntarily!
To prevent the lock between the end section 3 and the pivot section 2 from opening inadvertently, the
spring retainer 7 must also be inserted on point F.
Insert the spring retainer 7 on point F.
Check if the end section 3 and the reduction piece 2 are properly locked.
Remove the auxiliary rope 17 from the end section 3 and attach on point C.
Disengage the lever 16 with the assembly rod from the link 14 and pull downward.
Swing out the folding jib support 18 until the spring-loaded pin 9 engages again.
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11.5.2 Reduction piece removal, part 1

In order to unpin at the top of the point B, the hydraulic / mechanical assembly aid 22 must be used.
Close the knob 26 on the manual pump 25.
pin 21 can be unpinned.
Release and unpin the pin 21 on top.
Open the knob 26 on the manual pump 25.
Result:
– The hydraulic cylinder of the assembly aid 22 returns to the starting position.
Unpin the pins 24 and insert into bore 19 and secure.
CAUTION
Release the pin 20 on the bottom and unpin.
5.02 LIEBHERR 759

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11.5.3 Reduction piece removal, part 2
DANGER
Swing the folding jib backward until the swing cylinder 10 is locked to the folding jib.
Press button 450 and swing in the folding jib with the swing cylinder until the lock 43 engages
audibly.
DANGER
Danger of fatal injury when unpinning the pins 9!
If the pins 9 are unpinned before the lock 43 has engaged, then the folding jib will fall down and
possibly cause fatal injury to the assembly personnel.
The pins 9 may not be unpinned until the lock 43 has engaged and the manual lever 16 has been
secured with the safety bracket 15.
Secure the manual lever 16 with the safety bracket 15.

Release the pin 9 at point A, unpin and insert into transport retainer.
Press button 450 and swing the folding jib with swing cylinder in all the way.
Attach folding jib with the folding jib holder: Insert and secure pin 12.
Connect the hydraulic line to the hydraulic cylinder at the point E.
“Hydraulic folding jibs” have an overflow tank attached to the hydraulic cylinder. The overflow tank
must be emptied when it is full. Even when the folding jib is not carried along on the crane.
5.02 LIEBHERR 761

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11.6 Removal of 3-piece folding jib

DANGER
disassembly.
Attach auxiliary crane so that no sloping occurs!
Do not remove folding jib until it has been secured with the auxiliary crane to prevent it from falling!
or
rope slightly.
DANGER
pins.
parts being lifted!

Place the pins 52 into the transport retainer.
or
Attach folding jib extension 4 to the auxiliary crane and tighten the cables lightly.
Note
retainers.
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Place the folding jib extension down 4.
Hang the reduction piece 2 on the auxiliary crane and guide into the fork heads on the pivot
section 6.
or
Hang the reduction piece 2 with the end section 3 on the auxiliary crane and guide into the fork
heads on the pivot section 6.
Pin the reduction piece 2 to the pivot section 6: Pin the pins 50 on both sides from the outside to
the inside and secure.
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11.7 Removal of 4-piece folding jib

DANGER
disassembly.
Attach cables so that no sloping occurs!
or
rope slightly.
DANGER
pins.
parts being lifted!

Place the pins 54 and the pins 55 in the transport retainer.
or
Attach folding jib extension 4 to the auxiliary crane and tighten the cable lightly.
Place the pins 52 and the pins 53 in the transport retainer.
Attach folding jib extension 5 to the auxiliary crane and tighten the cable lightly.
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Note
retainers.
Hang the reduction piece 2 on the auxiliary crane and guide into the fork heads on the pivot
section 6.
or
Hang the reduction piece 2 with the end section 3 on the auxiliary crane and guide into the fork
heads on the pivot section 6.
Pin the reduction piece 2 to the pivot section 6: Pin the pins 50 on both sides from the outside to
the inside and secure.
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11.8 Removing the separately transported folding jib

– The end section is locked with the reduction piece.
See section “Disassembly of the end section”.
For description of fastening points, see section “Folding jib fastening points, complete”.
Attach the auxiliary crane to the relevant fastening points of the folding jib.
DANGER
Danger of accident when disassembling the folding jib!
Failing to comply with the following conditions may result in fatal injury to the assembly personnel
during disassembly.
Do not allow anyone to stand beneath the folding jib when the pins are being removed!
Attach the auxiliary crane so that no diagonal pull occurs!
Only lift a weight with the auxiliary crane that corresponds to the weight of the folding jib that is
being removed!
The folding jib may detach suddenly because of distortion!
Tighten the fastening ropes until the folding jib is secured to prevent it from falling.
Unpinning the folding jib from the telescopic boom:
Release the pin 9 on top on point A and unpin.
Release the pin 20 on top on point B and unpin.
Release the pin 9 on the bottom on point A and unpin.
Release the pin 21 on the bottom on point B and unpin.
Place the folding jib onto the transport vehicle.
Hydraulic folding jibs have an overflow tank attached to the hydraulic cylinder. The overflow tank must
be emptied when it is full. Even if the folding jib is not transported on the crane.
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1 General
Winch2 may be attached to this crane for the folding jib operation with a reeved telescopic boom or for
the dual hook operation.
Winch2 has a weight of approximately 1750 kg with the hoisting cable.
2 Assembly
– the crane is properly supported and level
– an auxiliary crane is always available
– the bolts 2 are attached and secured on both sides
2.1 Assemble winch2

Attach the auxiliary crane to the lugs 3.
Introduce winch2 1 with the auxiliary crane into the bolts 2.
Adjust winch2 1 until the holes in winch2 1 and the rotating platform are flush.
Bolt in bolts 4 on both sides and secure.
DANGER
Accident hazard due to possible drop of winch2!
Only unhook auxiliary crane after winch2 1 is bolted and secured!
Remove winch2 1 from the auxiliary crane.
2.2 Connect supply lines

Create electrical connections for winch2.
Create supply line for the central lubricating system.
Engine must be switched off before attaching and releasing hydraulic pipes.
The different diameters of the hydraulic lines prevent incorrect coupling.
Create hydraulic connections to winch2.
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3 Dismantling
– an auxiliary crane is available
3.1 Disconnecting the supply lines

The engine must be turned off prior to connecting and disconnecting hydraulic lines.
Remove hydraulic connections from winch2.
Remove electrical connection for winch2.
Disconnect the supply line for the central lubricating system.
Secure supply lines in the transporting fixures.
3.2 Dismantling the winch2

Wind up the hoisting cable of winch2 1.
Secure hoisting cable.
Block winch2 1 by LICCON program “Control parameters”.
Attach the auxiliary crane to the lugs 3.
DANGER
Accident hazard due to possible drop of winch2!
Only remove bolts 4 after winch2 is secured by the auxiliary crane.
Release and remove bolts 4.

Store winch2 1 on the transport vehicle.
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5.10 Boom nose 025981-00
1 General
The operation using the boom nose is equipped for quick lifts over the boom nose whereby the hook
block may remain reeved on the telescopic boom.
Please observe Chapter 4.12 during the operation with the boom nose.
The boom nose weights 125 kg.
Note
Load capacity tables
No special load capacity tables are available for boom nose operations. The boom nose is
generally run in the telescopic boom operating mode. The load, however, is reduced by the weight
of the boom nose, as well as that of the used load lifting devices and lifting tackles.
2 Assembly
2.1 Move boom nose to operation position, Fig. 1 and 2
DANGER
Accident hazard due to potentiall fall of the boom nose!
If the swivel pin 2 is unbolted, the boom nose drops.
Never unbolt the swivel pin 2!
Release bolts 3 and bolts 4 and unbolt.
CAUTION
Risk of crushing fingers!
Fingers may be crushed between the telescopic boom and the boom nose when turning the boom
nose.
Do not place fingers between the boom nose and the telescopic boom!
Turn boom nose 1 180 ° until the bolt 4 can be bolted at point B.
Attach bolt 4 and secure.
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2.2 Fold boom nose into operating position, Fig. 3 and 4

DANGER
Accident hazard due to possible fall of the boom nose!
Release bolts 6 at point C and unbolt.
CAUTION
Fingers may be crushed when folding the boom nose.
Do not crush fingers when folding the rope pulley 5!
Fold down rope pulley 5 until a bolt can be attached at point D.

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5.10 Boom nose 025981-00
2.3 Reeving the hoisting cable

Reeving is possible twice at the boom nose.
Cable securing tubes 8, release and unbolt.
Run hoist cable over pulley on the telescopic boom and the cable pulley 5.
Bolt in cable securing pipes 8 and secure.
Reeve in the load hook or hook block.
Attach hoisting limit switch weight.
2.4 Hoisting limit switch

The hoisting limit switch -S930, the air traffic warning light* and the wind sensor* remain attached to
the telescopic boom head.
If the hoist limit switch -S931 is assembled to the telescopic boom:
Dismantle the hoist limit switch -S931 on the telescopic boom and attach to the boom head.
2.5 Single hook operation

When working in the “single hook operation”, the hoist limit switch -S930 that is not required must be
manually operated.
Pull hoist limit switch 20 and attach 21 to fixed point 22 using shackle.
Manually operate hoist limit switch -S930.
2.6 Dual hook operation

In the dual hook operation, the hoist limit switch -S930 on the telescopic boom and the hoist limit
switch -S931 on the boom head are active!
2.7 Function check

The function check must be performed by the crane operator before starting up the crane and before
lifting a load.
The following checks must be performed.
Check that the hoist limit switch, wind sensor* and air traffic warning lamp* connections are
properly connected.
Check wind sensor operation* on LICCON monitor.
Check operation of air traffic warning lamp*.
Check movement of hoisting limit switches. The following steps are required to perform these checks.
Manually operate hoist limit switch.
Check that the “Hoist up” icon is displayed on the LICCON monitor for main boom and boom nose.
Check the shutoff of the hoisting winch.
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5.10 Boom nose 025981-00
3 Dismantling
3.1 Fold boom nose to transporting position, Fig. 5 and 6

Dismantle the hoist limit switch weight.
Reeve out load hook/hook block on the boom nose.
Cable securing tubes 8, release and unbolt.
Do not pull hoisting cable under the winch when winding up.
Wind up hoisting cable.
Note
During the operation without the boom nose, you must use the hoist limit switch -S931 either as
an additional hoist limit switch for the telescopic boom and/or mechanically pull the hoist limit
switch -S931 and attach it to the cable fixed point using shackles.
DANGER
Accident hazard due to falling boom nose!
Release bolts 6 at point D and unbolt.
CAUTION
Fingers may be crushed when folding the boom nose.
Do not crush fingers when folding the rope pulley 5!
Fold up rope pulley 5 until a bolt can be attached at point C.

Attach bolt 6 and secure
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5.10 Boom nose 025981-00
3.2 Swivel boom nose into transport position, Fig. 7 and 8

DANGER
Accident hazard due to falling boom head!
Release and unbolt the bolt 4.
CAUTION
Fingers may be crushed between the telescopic boom and the boom nose when turning the boom
nose.
Do not place fingers between the boom nose and the telescopic boom!
Turn boom nose 1 180 ° until the bolt 3 can be bolted at point A.
Attach and secure bolt 3.
Bolt and secure bolt 4 on the boom nose.
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025982-02 5.12 Auxiliary boom
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5.12 Auxiliary boom 025982-02
1 General
DANGER
Danger of accident when driving with the auxiliary boom!
Before being driven on roads, the auxiliary boom must always be brought to the transport position
and mechanically secured.
Make sure that the auxiliary boom is properly secured before driving the crane on public roads.
Note
Load reduction! With the hook block reeved on the telescopic boom, loads in auxiliary boom
operating modes must be reduced by the weight of the hook block.
1.1 Component overview
Position Description Length Weight

1 Pivot section
2 End section 3.4 m 0.8 t
1.2 Fastening point

Please refer to diagram.
Description Abbreviation
Auxiliary boom S
2 Installing the auxiliary boom

2.1 General
DANGER
Danger of fatal injury due to toppling auxiliary boom!
Due to an assembly error, the auxiliary boom could fall down.
Standing under the auxiliary boom during the swing operation is prohibited!
It is prohibited for anyone to remain within the swinging area or the folding area of the auxiliary
boom!
The auxiliary boom must be secured by an auxiliary rope during the swing process!
5.12 LIEBHERR 787

DANGER
Danger of falling!
from falling. If this is not observed, the assembly personnel could be fatally injured.
All assembly work must be carried out using suitable aids (ladders, lifting platforms, scaffolding,
auxiliary crane etc.)!

– The auxiliary boom is attached on the telescopic boom pivot section for transport.
DANGER
Danger of accident from involuntary swinging out of the auxiliary boom when it is unpinned!
of the auxiliary boom when it is unpinned.
2.2 Reeving out the hoist rope on the telescopic boom head
Extend the telescopic boom to a length of approximately 4 m.
Place the hook block on the ground.
Disengage the hoist rope on the rope fixed point.
Disassemble the hoist limit switch weight and the chain for safety reasons.
Note
The hoist limit switch must be pulled mechanically and the operating cable must be attached to the
telescopic boom head with the snap hook when operating the auxiliary boom.
The telescopic boom may remain reeved in, if the hoist rope of winch 2 is used for auxiliary boom
operation.
Remove the rope retaining pipes on the pulley head and on the back pulley.
Telescope the telescopic boom in again completely.
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2.3 Assembly of the auxiliary boom carried on the crane
2.3.1 Swinging the auxiliary boom into operating position

Swivel auxiliary boom out until it can be pinned at point A.
DANGER
the pins 4 is not permitted. The auxiliary boom may only be released at point D if the pins 4 are
Swing the safety bracket 5 with the assembly rod to the side.
Push the lever 6 with the assembly rod up and latch into the bracket 7.
DANGER
Standing in the slewing area or the folding area of the auxiliary boom is prohibited!
Swing the auxiliary boom with the auxiliary rope 9 by 180 ° until it can be pinned at point B on the
top and bottom.
DANGER
The use of spring springs or spring retainers is prohibited on the pins 8!
Insert the pins 8 at the top and at the bottom at point B and secure.
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2.3.2 Folding the end section into operating position
DANGER
Danger of fatal injury in case of defective pneumatic spring!
Defective pneumatic springs 41 no longer provide the supporting action for the movable components
on the auxiliary boom!
If the pneumatic spring 41 is defective, the end section 2 can fall down and fatally or seriously injure
personnel!
There is an increased danger of accidents!
Before unpinning the spring pin 10 and before actuation, check the pneumatic spring 41 for
external damage!
Do not use auxiliary boom with defective pneumatic spring 41! Replace defective pneumatic
springs 41!
If the pneumatic spring 41 is defective, support the end section 2 from below or hang it on an
auxiliary crane.
It is strictly prohibited for personnel or objects to remain within the movement range between the
end section 2 and the pivot section 1!
components!
Attach the auxiliary rope 9 at point E.
DANGER
Risk of accident!
Before unpinning the spring pins 10 it must be ensured that no persons or objects are in the danger
zone, particularly between the end section 2 and the pivot section 1.
Unpin the spring pin 10 only if there are no persons or objects in the danger zone!
Hang the snap hook 20 on the eye 21 of the spring pin 10.
Hang the assembly rod 22 on the snap hook 20 and pull the spring pin 10.
Fold the end section 2 down with the auxiliary rope 9 until the spring pin 10 engages again.
DANGER
Risk of accident!
Before operation with the auxiliary boom can be started, the end section 2 must lie against the
pivot section 1 and be pinned with the spring pin 10.
Check whether the auxiliary boom has been pinned as described in the operating instructions.
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2.4 Assembling the separately transported auxiliary boom

DANGER
Do not allow anyone to stand beneath the auxiliary boom during installation!
Attach auxiliary boom at attachment point and insert into pinning points of telescopic boom.
DANGER
The use of spring pins or retaining pins on the pins 4 and pins 8 is prohibited!
To secure the pin 4 and the pin 8, use the special safety clips.
Pin the auxiliary boom to the telescopic boom:

Pin and secure the pin 4 on top on point A.
Pin and secure the pin 4 on the bottom at point A.
For the rest of the assembly see section “Folding the end section into operating position”.
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2.5 Reeving in the hoist rope

DANGER
Danger of falling from auxiliary boom!
When walking on the auxiliary boom to reeve the hoist rope in or out, there is a risk of slipping and
falling from the auxiliary boom.
Do not walk on the auxiliary boom!
Release and unpin rope retaining pin 11, rope retaining pin 12 , rope retaining pin 13 and rope
retaining pin 14.
Run hoist rope over rope guide pulley 15, rope guide pulley 16 and rope guide pulley 17.
Pin all rope retaining pins in again and secure with linch pins.
Reeve in the hoist rope. See chapter “4.06 Rope reeving”.
Attach the hoist limit switch weight.
Note
The weight of the hook block that is reeved into the telescope boom must be deducted from the
load during auxiliary boom operations with the hook block reeved into the telescope boom.
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2.6 Electrical connections on auxiliary boom
2.6.1 Mechanically actuating the hoist limit switch, illustration 1

If you are working in “single hook mode” when using the auxiliary boom, the hoist limit
switch -S930/-S931 that is not required must be operated manually.
Pull the hoist limit switch rope 20 and attach to the fixed point 22 with the shackle 21.
2.6.2 Electrical connections

Single hook operation, illustration 3
Note
Only the hoist limit switch S940 on the auxiliary boom is active during single hook operation.

Insert the cable plug -X556 into the socket -X500H.
Two hook operation, illustration 3
Note
switch S940 on the auxiliary boom are active!

Insert the cable plug -X556 into the socket -X500H.
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2.6.3 Function check

– The LICCON computer system is running.
Wind sensor
CAUTION
The wind velocity can no longer be determined if a defective wind sensor is installed.
Check the function of the wind sensor every time it is installed.
Manually actuate the wind sensor.

Result:
– The icon element “Wind velocity” 2.2 appears on the monitor.
Hoist limit switch

Actuate all active hoist limit switches manually.
Result:
– The appropriate icon element “Hoist top” appears on the monitor.
– The winch turns off.
Note
When replacing or changing the hoist limit switch, the hoist limit switch must have the correct bus
address and the correct software version in order to be detected by the bus system.
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3 Erection
3.1 Preparatory work

– The auxiliary boom has been assembled according to the load chart and the operating
instructions.
– The hoist rope has been correctly placed in the cable pulleys and is secured with the rope
retaining pins to prevent it from jumping out.
– There are no loose parts on the telescopic boom or the auxiliary boom.
– The telescopic boom, the auxiliary boom and its components (such as: limit switch, airplane
warning light, wind speed sensor) must be free of snow and ice in winter.
DANGER
Risk of accident!
Incorrectly installed or non-functioning limit switches as well as falling parts (such as: pins, spring pins,
ice) can cause accidents!
Assemble all limit switches, pins and spring pins properly.
Check if all preconditions have been met.
3.2 Erection procedure

DANGER
The radii specified in the load chart may not be exceeded or fallen below, even if there is no load on
the hook! If this regulation is not observed, the crane can topple over.
Compare and check the settings on the LICCON computer system with the actual configuration
status!
Adjustment of the LICCON overload protection, refer to chapter 4.02.

Set and confirm the LICCON overload protection according to the required set up configuration.
Luff the telescopic boom up with installed auxiliary boom until the LICCON issues the release.
Telescope the telescopic boom out to values specified in load chart.
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4 Unreeving the hoist rope
DANGER
Danger of falling from auxiliary boom!
When walking on the auxiliary boom to reeve the hoist rope in or out, there is a risk of slipping and
falling from the auxiliary boom.
Do not walk on the auxiliary boom!
4.1 Unreeving the hoist rope

– The hook block / load hook has been put down on the ground.
– The hoist rope is attached to the rope fixed point.
– The hoist limit switch weight and the chain have been removed.
Release and unpin rope retaining pin 11, rope retaining pin 12 , rope retaining pin 13 and rope
retaining pin 14.
Spool up the hoist rope.
Re-pin rope retaining pin 11, rope retaining pin 12, rope retaining pin 13 and rope retaining
pin 14 and secure with linch pins.
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5 Dismantling the auxiliary boom
5.1 General
DANGER
The auxiliary boom may topple if it is incorrectly disassembled.
It is prohibited for anyone to remain within the swinging area or the folding area of the auxiliary
boom!
The auxiliary boom must be secured by an auxiliary rope during the slewing process!
DANGER
Danger of falling!
from falling. If this is not observed, the assembly personnel could be fatally injured.
All assembly work must be carried out using suitable aids (ladders, lifting platforms, scaffolding,
auxiliary crane etc.)!

– The electrical connection of the auxiliary boom has been disconnected.
DANGER
Danger of accident from involuntary swinging out of the auxiliary boom when it is unpinned!
The telescopic boom must be in 0° position, otherwise there is a risk of accident due to involuntary
swinging out of the auxiliary boom when it is unpinned.
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5.2 Dismantling the auxiliary boom carried on the crane
5.2.1 Folding the end section into transport position

Hang the assembly rod 22 on the snap hook 20 and pull the spring pin 10.
Fold the end section 2 up with the assembly rod 22 until the spring pin 10 engages again.
DANGER
Risk of accident!
The spring pin 10 must be engaged and secured before the auxiliary boom is swung into transport
position.
Engage and secure the spring pin 10.
DANGER
Danger of fatal injury in case of defective pneumatic spring!
Defective pneumatic springs 41 no longer provide the supporting action for the movable components
on the auxiliary boom!
If the pneumatic spring 41 is defective, the end section 2 can fall down and fatally or seriously injure
personnel!
There is an increased danger of accidents!
Before unpinning the spring pin 10 and before actuation, check the pneumatic spring 41 for
external damage!
Do not use auxiliary boom with defective pneumatic spring 41! Replace defective pneumatic
springs 41!
If the pneumatic spring 41 is defective, support the end section 2 from below or hang it on an
auxiliary crane.
It is strictly prohibited for personnel or objects to remain within the movement range between the
end section 2 and the pivot section 1!
components!
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5.2.2 Swivelling the auxiliary boom into the transport position

DANGER
The auxiliary boom may swing out involuntarily!
While unpinning the pin 8, the auxiliary boom can swing out unintentionally.
In order to prevent the auxiliary boom from involuntarily swinging out:
Hold down auxiliary boom using the auxiliary rope!
Do not lean the ladder against the auxiliary boom!
Release the pin 8 on point B and unpin.

Disengage the hand lever 6 with the assembly rod from the platform 7 and pull downward.
Swing the auxiliary boom in with the auxiliary rope 9 until the lock 18 audibly engages.
Secure hand lever 6 with retaining bracket 5.
DANGER
If the pins 4 are unpinned before the lock 18 has audibly engaged, the auxiliary boom will fall down
and possibly cause fatal injury to the assembly personnel.
The pins 4 may not be unpinned until the lock 18 has audibly engaged and the hand lever 6 has
been secured with the safety strap 5.
Release the pin 4 on point A and unpin.

Swing the auxiliary boom in until the spring pin 3 engages.
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5.3 Removing the separately transported auxiliary boom

Attach the auxiliary crane on the fastening point of the auxiliary boom.
DANGER
Danger of accident when removing the auxiliary boom!
Failing to comply with the following conditions may result in fatal injury to the assembly personnel
during disassembly.
When knocking out the pins, no personnel may remain under the auxiliary boom!
Attach the auxiliary crane so that no diagonal pull occurs!
Only lift a weight with the auxiliary crane that corresponds to the weight of the auxiliary boom that
is being removed!
The auxiliary boom may detach suddenly because of distortion!
Do not remove auxiliary boom until it has been secured with the auxiliary crane to prevent it from
falling!
Do not lean the ladder against the auxiliary boom!
Tighten the ropes so that auxiliary boom is prevented from falling.

Unpinning the auxiliary boom from the telescopic boom:
Release the pin 4 on top on point A and unpin.
Release the pin 8 on top on point B and unpin.
Release the pin 4 on the bottom on point A and unpin.
Release the pin 8 on the bottom on point B and unpin.
Place the auxiliary boom onto the transport vehicle.
5.12 LIEBHERR 813

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5.19 Hook blocks 028062-01
1 Minimum required hook block weight
WARNING
Falling components and hook block!
If the chosen hook block weight is not large enough. then the hoist rope pulls the hook block between
the boom head and the winch from a certain hoisting height suddenly upward. As a result, the boom
head and the hook block can be damaged. Damaged components and the hoist rope between the
boom head and the winch can fall down.
If slack rope forms between the winch and the boom head when spooling the winch out, then the hook
block can suddenly fall down.
Calculate the minimum required hook block weight before lifting the load!
Select the weight of the hook block depending on the calculation!
If the weight of the hook block is not sufficient:
Select a heavier hook block or increase the weight of the hook block with fastening items, load
tackle, auxiliary weights or modification kits!
NOTICE
Rope damage due to insufficient weight of the hook block!
If the hook block is operated with a higher reeving than is required by the load on the respective boom
length, the minimum required hook block weight increases.
If the hook block weight is too low to tighten the hoist rope sufficiently, spooling problems may occur
on the winches when lowering and lifting the hook block due to slack rope formation. Rope damage
can result.
If no minimum system-related hoist reeving is required for the operating mode:
Reeve the hook block at the minimum depending on the maximum rope pull and the weight of the
load to be lifted!
If the weight of the hook block is not sufficient:
Select a heavier hook block or increase the weight of the hook block with fastening items, load
tackle, auxiliary weights or modification kits!
Note
Recommendation for selection of hook block weight!
If the maximum load capacity for the respective boom configuration is not exceeded by an additional
weight increase of the hook block:
Increase the minimum required hook block weight additionally by at least 10%!
If an additional weight increase of the hook block due to the maximum load capacity for the respective
boom configuration is not possible:
Lower the hook block only with utmost caution!
Note
Observe the permissible hook block weights for erection and take down of the boom system!
If the permissible hook block weight for erection and take down of the boom system is exceeded due
to the own weight increase of the hook block, then the boom system cannot be erected or taken down
with this hook block weight.
Observe the permissible hook block weights for erection and take down in the erection and take
down charts!
If the permissible hook block weight for erection and take down is exceeded:
Remove auxiliary weights for the erection and take down of the boom system!
1.1 Calculating the minimum required hook block weight
5.19 LIEBHERR 815

028062-01 5.19 Hook blocks
Formula to determine the minimum required hook block weight
Abbreviation Description Unit

G Minimum required hook block weight kg
L Overall boom length m
M Rope weight kg/m
N Reeving -
F Factor -
Explanation of variables to calculate the minimum required hook block weight
1.2 Determining the rope weight for the rope diameter
Rope diameter Rope weight M

13 mm 0.85 kg/m
15 mm 1.12 kg/m
17 mm 1.45 kg/m
19 mm 1.81 kg/m
21 mm 2.24 kg/m
23 mm 2.67 kg/m
25 mm 3.09 kg/m
28 mm 3.94 kg/m
30 mm 4.46 kg/m
32 mm 5.09 kg/m
38 mm 7.21 kg/m
40 mm 7.99 kg/m
52 mm 13.50 kg/m
Rope diameter and rope weight
1.3 Determining the factor for reeving
Reeving N Factor F
1 1.31
2 1.34
3 1.36
4 1.39
5 1.41
6 1.44
7 1.46
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5.19 Hook blocks 028062-01
Reeving N Factor F
8 1.49
9 1.52
10 1.54
11 1.57
12 1.60
13 1.63
14 1.65
15 1.68
16 1.71
17 1.74
18 1.77
19 1.80
20 1.83
21 1.87
22 1.90
23 1.93
24 1.96
25 2.00
26 2.03
27 2.06
28 2.10
29 2.13
30 2.17
Reeving and factor
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028062-01 5.19 Hook blocks
1.4 Calculation examples
1.4.1 Calculating the required hook block weight for crane operation with 1 hoist
rope winch in single operation with single hook block
Crane configuration:
– Length of main boom: 70 m
– Length of auxiliary boom: 28 m
– Rope diameter: 28 mm
– Reeving: 12 rope strands
Variables for calculation:
L = overall boom length = 98 m
M = rope weight for rope diameter 28 mm = 3.94 kg/m
N = reeving = 12
F = Factor for 12 rope strands = 1.60
Calculation:
G=LxMxNxF
G = 98 m x 3.94 kg/m x 12 x 1.60
G = 7414 kg
The minimum required hook block weight must be 7414 kg and must be increased additionally by at
least 10 % (741 kg) to 8155 kg. The maximum load capacity for the respective boom configuration
may not be exceeded by the additional weight increase of the hook block.
1.4.2 Calculating the required hook block weight for crane operation with 2 hoist
rope winches in parallel operation with double hook block
Crane configuration:
– Length of main boom: 70 m
– Length of auxiliary boom: 28 m
– Rope diameter: 28 mm
– Reeving: 2 x 8 rope strands
Variables for calculation:
L = overall boom length = 98 m
M = rope weight for rope diameter 28 mm = 3.94 kg/m
N = reeving = (2 x 8)
F = Factor for 8 rope strands = 1.49
Calculation:
G = L x M x (2 x N) x F
G = 98 m x 3.94 kg/m x (2 x 8) x 1.49
G = 9205 kg
The minimum required hook block weight must be 9205 kg and must be increased additionally by at
least 10 % (921 kg) to 10126 kg. The maximum load capacity for the respective boom configuration
may not be exceeded by the additional weight increase of the hook block.
2 Procedure in case of slack rope

2.1 Lowering the hook block if slack rope forms
If the hook block can no longer be lowered due to slack rope formation, then the following steps must
be carried out.
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5.19 Hook blocks 028062-01
2.1.1 Spooling op loose hoist rope

Spool up loose hoist rope between the boom head and the wind carefully onto the winch.
Note
A slight rope slack must remain between the boom head and the winch!
2.1.2 Luffing the boom down
NOTICE
Risk of collision!
When luffing the boom down, the hoist rope length can shorten and pull the hook block against the
boom head.
Monitor the distance of the hook block to the boom head!
Luff the boom down carefully.

Result:
– The hoist rope between the boom head and the winch is tensioned.
2.1.3 Lowering the hook block

Lower the hook block carefully with the hoist gear.
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5.19 Hook blocks 028062-01
3 Hook block overview
3.1 Handling of hook blocks

Note
For the load hooks and hook blocks approved for this crane type refer to the separate load chart
manual!
The hook blocks shown in this chapter are only examples and can differ from your hook block in
type and number of rope pulleys. The different assembly and disassembly procedures are
therefore only an example of the description for a number of different hook blocks!
DANGER
Hook block weights!
If the data in the erection and take down charts as well as the load charts are not observed,
dangerous situations up to toppling of the crane can occur!
Personnel can be severely injured or killed, in addition, high property damage can result!
Observe the data in the erection and take down charts!
The crane operator bears the sole and full responsibility for the adherence to the data in the
erection and take down charts as well as the load charts!
Differently sized hook blocks can be used for various loads.
NOTICE
Rope damage due to insufficient hook block weight!
If the hook block weight is too low to tighten the hoist rope sufficiently, spooling problems may occur
on the winches when lowering and lifting the hook block due to slack rope formation!
The hoist rope can be damaged!
In order to prevent spooling problems on the winches, the hook block weight may be increased
with auxiliary weights, if necessary!
If problems develop in the assembly and set up conditions due to the weight increase of the hook
block, auxiliary weights must be removed again!
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5.19 Hook blocks 028062-01
4 Installing the single blocks
4.1 Installing the auxiliary weights

Note
Each auxiliary weight's own weight is marked on the auxiliary weight!
WARNING
Toppling of hook block!
If the auxiliary weights are installed one-sided, the hook block can topple over!
The auxiliary weights may only be installed individually and alternately on the left and right on the
hook block!
When the required auxiliary weight is installed on the hook block, the difference between the left
and right side may never be more than one auxiliary weight!
Asymmetrical installation of auxiliary weights is prohibited!

– The hook block is placed on the ground.
WARNING
Falling auxiliary weights!
If the auxiliary weights are not properly installed on the hook block, then they can fall down during
installation or in crane operation!
Standing under a suspended auxiliary weight is prohibited!
Make sure that the auxiliary weights are properly installed and secured!
Crane operation with insufficiently secured auxiliary weights is prohibited!
Attach the auxiliary weight 10 on the ring screw 14 on the auxiliary crane.
WARNING
Danger of crushing!
When swinging the auxiliary weights to the hook block, personnel can be severely injured or killed!
Fingers, hands and arms can be crushed or severed!
It is prohibited for anyone to remain between the hook block and the auxiliary weight!
Swing auxiliary weights in to the hook block with utmost caution and at the least possible speed!
5.19 LIEBHERR 823

028062-01 5.19 Hook blocks
B108965
824 LIEBHERR 5.19

5.19 Hook blocks 028062-01
Align the auxiliary weight 10 on the hook block.

Move the centering pin 10.1 of the auxiliary weight into the centering bores P1 on the hook block.
WARNING
If all mounting brackets are removed simultaneously on an unsecured auxiliary weight, then the
auxiliary weight can fall down!
Never remove all mounting brackets of an unsecured auxiliary weight at the same time!
Always install or remove the mounting brackets alternately!
Install the mounting brackets 11 on the side and connect the hook block with the auxiliary
weight 10, illustration 3.
Secure the mounting brackets 11 with screws 12 and lock nuts 13, illustration 3.
Note
Additional auxiliary weights must be connected with the mounting brackets 11!
WARNING
The auxiliary weights can fall down by removing the auxiliary crane!
Remove the auxiliary crane only when it is ensured that the auxiliary weight 10 is properly secured
with the mounting brackets 11!
When the respective auxiliary weight is properly installed and secured:

4.2 Preparing the hook block for crane operation

Note
The reeving of the hook blocks is described in chapter 4.06 of the Crane operating instructions!
Observe the “permissible hook block weights” in the erection and take down charts!
Reeve the hoist rope according to the instructions in chapter 4.06 of the Crane operating
instructions and the reeving plans!
5.19 LIEBHERR 825

028062-01 5.19 Hook blocks
B108965
826 LIEBHERR 5.19

5.19 Hook blocks 028062-01
5 Removing the single blocks
5.1 Preparing the hook block for removal

Note
The unreeving of the hook blocks is described in chapter 4.06 of the Crane operating instructions!
Observe the “permissible hook block weights” in the erection and take down charts!

– The ground is sufficiently load bearing to take on the weight of the hook block and the auxiliary
weights safely.
– The ground is level and horizontal.
Lower the hook block completely to the ground.
When the hook block was placed down on the ground properly:
Unreeve the hoist rope according to chapter 4.06 of the Crane operating instructions!
5.2 Removing the auxiliary weights

Note
Each auxiliary weight's own weight is marked on the auxiliary weight!
WARNING
Toppling of hook block!
If the auxiliary weights are removed one-sided, the hook block can topple over!
The auxiliary weights may only be removed individually and alternately on the left and right on
the hook block!
The difference between the left and the right side at removal of the auxiliary weights may never be
more than one auxiliary weight!
Asymmetrical removal of auxiliary weights is prohibited!
WARNING
If the auxiliary weights on the pulley block are not properly removed, then they can fall down at
removal!
Standing under a suspended auxiliary weight is prohibited!
Attach the auxiliary weight 10 on the ring screw 14 on the auxiliary crane.
Tension the tackle carefully.
5.19 LIEBHERR 827

028062-01 5.19 Hook blocks
B108965
828 LIEBHERR 5.19

5.19 Hook blocks 028062-01
WARNING
Oscillating auxiliary weights!
During the removal of the auxiliary weights, the auxiliary weights can start to swing back and forth!
Make sure that the auxiliary weight which is being removed is properly attached on the auxiliary
crane before releasing the mounting brackets!
When the tackle is tensioned on the auxiliary weight:

Release the screw connection on the mounting brackets of the outermost auxiliary weight and
remove the screws.
WARNING
If all mounting brackets are removed simultaneously on an unsecured auxiliary weight, then the
auxiliary weight can fall down!
Never remove all mounting brackets of an unsecured auxiliary weight at the same time!
Always install or remove the mounting brackets alternately!
Pull the mounting brackets 11 off to the side.
WARNING
If additional auxiliary weights which are being removed are released, then these auxiliary weights can
fall down!
Make sure, before removing the outermost auxiliary weight, that the other auxiliary weights are
secured with the mounting brackets!
If additional mounting brackets must be removed to release the outermost auxiliary weight:
Reinstall the mounting brackets again immediately, so that only the auxiliary weight which is being
removed is released.
Lift the auxiliary weight with the auxiliary crane from the hook block.
Place the auxiliary weight onto the ground.
Remove additional auxiliary weights as described above.
5.19 LIEBHERR 829

025983-00 5.25 Telescopic boom extension
B196448
830 LIEBHERR 5.25

5.25 Telescopic boom extension 025983-00
1 General
In order to increase the hoisting height, a 7 m long telescopic boom extension may be attached to this
crane.
1.1 Attachment points Telescopic boom extension

A special attachment point is available for the assembly/dismantling of the telescopic boom extension.
The attachment point is marked by a tag.

Telescopic boom extension TV 0.7 t
5.25 LIEBHERR 831

B196448
832 LIEBHERR 5.25

2 Assembly
DANGER
Accident hazard during the assembly/dismantling of the telescopic boom extension!
If the following conditions are not fulfilled, people may be fatally injured during the
assembly/disassembly.
People may not stand below the telescopic boom extension when bolts are removed!
Remove or insert the bolts in the sequence specified in the operating instructions!
Attach or remove bolts from the top down!

– the counterweight is attached to the rotating platform according to the load capacity table
– the telescopic boom is completely retracted
– the telescopic boom is lowered toward the back or toward the side in 0° position
2.1 Assembly process

Telescopic boom extension 7, attach to auxililary crane and insert into yokes on the telescopic
boom.
Bolt telescopic boom extension 7 to telescopic boom: Attach bolts 10 on both sides from the top
down and secure.
Attach bolts 11 on both sides from the top down and secure.
Refer to Chapter 5.02 for the attaching points of the folding jib.
Attach folding jib to the auxiliary crane and insert into the yokes at the telescopic boom
extensions 7.
Attach folding jib to the telescopic boom extension 7: Attach bolts 12 on both sides from the top
down and secure.
Refer to Chapter 5.02 for the subsequent asssembly of the folding jib.
Completely assemble the folding jib.
5.25 LIEBHERR 833

B192188
834 LIEBHERR 5.25

3 Create electrical/hydraulic connections
3.1 Create hydraulic connection

A hydraulic connection to the folding jib must only be produced at a hydraulic angular adjustment
(TNZK operation). Hydraulic lines cannot be incorrectly connected due to the varying diameters of the
hydraulic connections.
For operations with a hydraulic folding jib:
Create hydraulic connections.
After operations with a hydraulic folding jib:
Protect connections from pollutants.
3.2 Create electrical connection

Insert cable plug -X500F in bushing -X556V.
Insert cable plug -X500 in the bushing -X500G.
Refer to Chapter 5.02 for additional connections of the folding jib.

Create electrical connection for the folding jib.
4 Setting up
Perform the set-up process according to Chapter 5.02.
5.25 LIEBHERR 835

B196448
836 LIEBHERR 5.25

5 Dismantling
DANGER
Accident hazard during the assembly/dismantling of the telescopic boom extension!
If the following conditions are not fulfilled, people may be fatally injured during the
assembly/disassembly.
People may not stand below the telescopic boom extension when bolts are removed!
Remove or insert the bolts in the sequence specified in the operating instructions!
Attach or remove bolts from the top down!

– the counterweight is attached to the rotating platform according to the load capacity table
– the telescopic boom is completely retracted
– the telescopic boom is lowered to the rear or to the side in 0° position
– the folding jib is in 0° position
– the electrical and hydraulic lines are disconnected
5.1 Dismantling process

Attach folding jib to auxiliary crane and lighty tighten the cable.
Release bolts 12 on both sides and unbolt from the top down.
Troubleshooting
Is it difficult to remove the bolts?
The bolts are distorted due to angular tightening, excessive or low hoisting force of the auxiliary crane.
Do not remove difficult to remove bolts by force!
Store folding jib.
Attach telescopic boom extension 7 to the auxiliary crane and tighten the cables lightly.
Store telescopic boom extension 7.
The following actions are only necessary, if the folding jib must be driven with the crane.
Attach folding jib to the auxiliary crane and insert in the yokes on the telescopic boom.
Attach folding jib to the telescopic boom: Attach bolts 10 on both sides from the top down and
secure.
Refer to Chapter 5.02 for the subsequent dismantling of the folding jib.
Completely dismantle the folding jib.
5.25 LIEBHERR 837

026724-00 5.27 Erection and take-down charts
B198140
838 LIEBHERR 5.27

5.27 Erection and take-down charts 026724-00
1 General
The hook block weight is the weight that is required to lift the maximum load using the respective
boom combination.
DANGER
Risk of accident if crane is overloaded or overturns!
Do not reeve a larger hook block that the one that is required to lift the maximum load specified in
the load chart.
2 Setup and takedown chart for the T-operation

The telescopic boom can be fully lowered as far as the specified distances without LMB monitoring.
Additional assembly parts, for example, the auxiliary boom, may not be attached.
Boom position, T-operation

toward the side
Counterweight toward the rear wide support reduced support
[t] base base
74 T-60.1 T-60.1 T-60.1
54 T-60.1 T-60.1 T-52.0
44 T-60.1 T-60.1 T-43.4
42 T-60.1 T-60.1 T-43.4
34 T-56.3 T-56.3 T-34.8
32 T-52.0 T-52.0 T-34.8
22 T-39.1 T-39.1 T-21.9
12 T-26.2 T-26.2 T-21.9
0 T-21.9 T-21.9 T-17.6
3 Setup and takedown chart for the TK/TNZK

operation
The telescopic boom T-13.3 (0/0/0/0/0) can be completely lowered with the specified folding jib
lengths without any LMB monitoring.
Boom position, TK/TNZK operation

toward the side
[t] base base
74 K-36.0 K-36.0 K-36.0
54 K-36.0 K-36.0 K-36.0
44 K-36.0 K-36.0 K-36.0
5.27 LIEBHERR 839

026724-00 5.27 Erection and take-down charts
Boom position, TK/TNZK operation

toward the side
[t] base base
42 K-36.0 K-36.0 K-36.0
34 K-36.0 K-36.0 K-36.0
32 K-36.0 K-36.0 K-36.0
22 K-36.0 K-36.0 K-36.0
12 K-36.0 K-36.0 -
0 K-22.0 K-22.0 -
4 Setup and takedown chart for the TVK/TVNZK

operation
The telescopic boom T-13.3 (0/0/0/0/0) can be completely lowered with the specified folding jib length
V-7.0 without any LMB monitoring.
Boom position, TVK/TVNZK operation

toward the side
[t] base base
74 K-36.0 K-36.0 K-36.0
54 K-36.0 K-36.0 K-36.0
44 K-36.0 K-36.0 K-36.0
42 K-36.0 K-36.0 K-36.0
34 K-36.0 K-36.0 K-36.0
32 K-36.0 K-36.0 K-36.0
22 K-36.0 K-36.0 K-29.0
12 K-36.0 K-36.0 -
0 - - -
840 LIEBHERR 5.27

6.00 Additional equipment
LIEBHERR 841
026720-00 6.01 Heater / engine pre-heating
B198440
842 LIEBHERR 6.01

6.01 Heater / engine pre-heating 026720-00
1 Heating the driver's cab

The cab can be heated using three different types of heating which are independent of each other:
– engine-dependent heating
– engine-independent auxiliary heating with engine preheating, at outside temperature of up to -40
°C, WEBASTO; Thermo 90 S*
– engine-independent auxiliary heating with engine preheating, at outside temperature of less than
-40 °C, WEBASTO; DBW 2020*, Air Top 5000*
Individual adjustment of the heating (for both engine-dependent and engine-independent auxiliary
heating*) is carried out using the operating elements beneath the crane operator's seat and using the
switches and control lights on the instrument panel.
CAUTION
Risk of damage to the heating control units* when carrying out electrical welding operations on the
crane!
Remove the negative and positive cables from the vehicle and crane superstructure batteries and
apply the positive cable respectively to the vehicle earth.
1.1 Heater operation
1.1.1 Adjusting the temperature

The cab is heated using the engine coolant. The temperature may be set in 7 different temperature
stages (0=“cold” to 6=“warm”.
Note
The selected settings are maintained after the ignition is switched off.
If you want to increase the temperature:

Press button 145.
Result:
– The display unit 114 briefly displays the temperature level set.
If you want to decrease the temperature:

Press button 146.
Result:
– The display unit 114 briefly displays the temperature level set.
6.01 LIEBHERR 843

B198440
844 LIEBHERR 6.01

1.1.2 Adjusting the ventilation

The ventilation speed can be set in four different stages (0=“off” to 3=“maximum ventilation speed”).
If you want to increase the fan speed:
Press button 147.
Result:
– The display unit 114 briefly displays the set fan speed.
If you want to decrease the fan speed:

Press button 148.
Result:
– The display unit 114 briefly displays the set fan speed.
1.1.3 Adjusting the recirculated air/fresh air

The supply of fresh air into the cab can be controlled using the button 153 and the button 154.
Recirculated air but- Fresh air button 154 Air distribution

ton 153
On Off Recirculated air only
Off On Fresh air only
On On Approx. 70% recirculated air and 30% fresh air
Off Off Approx. 30% recirculated air and 70% fresh air
Press button 153.

Result:
– The button 153 has been switched on.
Press button 154.

Result:
6.01 LIEBHERR 845

B198440
846 LIEBHERR 6.01

1.1.4 Ventilating the footwell/windscreen

The supply of fresh air into the cab can be controlled using the button 155 and the button 156.
Footwell button 155 Windscreen button 156 Air distribution

On Off Footwell only
Off On Windscreen only
On On Approx. 70% footwell and 30% windscreen
Off Off Approx. 30% footwell and 70% windscreen
Press button 155.

Result:
Press button 156.

Result:
1.1.5 Adjusting the air distribution

Open air vent 44.
Result:
– Air distribution takes place.
Close the air vent 44.

Result:
– The air distribution is completed.
6.01 LIEBHERR 847

B198440
848 LIEBHERR 6.01

1.2 Operating engine-independent auxiliary heating*

The engine-independent auxiliary heating is used to heat the cab when the engine is turned off and as
auxiliary heating* at low ambient temperatures if the engine-dependent heating is insufficient.
You can find a full description of the auxiliary heating* in the manufacturer's accompanying operating
instructions.
During the summer, run the auxiliary heating* once a month for approx. 15 to 20 minutes.
Carry out maintenance work on the auxiliary heating* in accordance with the manufacturer's
accompanying operating instructions.
1.2.1 Starting up
CAUTION
Risk of damage to auxiliary heating!
Fill all units with sufficient operating materials for winter operation in accordance with the lubricant
chart.
DANGER
Risk of poisoning and suffocation in enclosed areas.
Only operate the heating device with preselect clock in enclosed areas such as garages or
workshops if waste gas suction is present.
DANGER
Danger of explosion!
In areas where combustible fumes or dust could form, e.g. in the vicinity of storage areas for fuel,
coal, wood dust or grain or similar and in the vicinity of filling stations or tank farms, there is a risk of
explosion.
Turn off the heating device.
Press button 144.

Result:
– The control light 180 lights up.
– The fan comes on automatically at level 1 in order to prevent the auxiliary heating from
overheating.
6.01 LIEBHERR 849

B198440
850 LIEBHERR 6.01

1.2.2 Turning off

Press button 144.
Result:
– The function control on button 144 goes out.
– Tracking takes place each time the auxiliary heating is turned off.
The keypad unit remains on even if the ignition key has been removed.
CAUTION
Only switch off the main battery switch once the heating device has finished tracking.
Once tracking is completed:

– the control light 180 goes off
– the keypad unit switches off automatically
1.2.3 Operation with preselect clock*

You can find a full description of the preselect clock 29 in the provided manufacturer's operating
instructions.
Set the required switch-on time, temperature and duration of the heating operation on the
preselect clock 29.
1.2.4 Venting the system

When draining off the engine coolant, the contents of the heating system will also be drained because
the engine and heating operate as one circuit. When refilling, the system should be carefully
deaerated.
Fill the coolant above the equalizing reservoir of the engine cooling circuit in accordance with the
lubricant chart.
Start the engine as described in Chapter 3.04.
Set the button 145 to level 3.
Observe the equalizing reservoir for air bubbles.
Result:
– The engine is deaerated as soon as no more air bubbles occur.
Once no more air bubbles appear in the equalizing reservoir:

Set the button 146 for the cab temperature to level 0.
Result:
– The heating circuit will be deaerated.

Result:
– The heating circuit is deaerated as soon as no more air bubbles occur.
6.01 LIEBHERR 851

B198440
852 LIEBHERR 6.01

1.3 Operating engine-independent auxiliary heating for engine

pre-heating*
At ambient temperatures of less than -20 °C the drive motor must be pre-heated using the engine
pre-heating facility.
At ambient temperatures of under -40 °C, the drive motor, fuel injection pump and transmission must
be preheated using preheating that is operated with diesel fuel.
You can find a full description of the engine preheating in the manufacturer's accompanying operating
instructions.
1.3.1 Starting up
CAUTION
chart.
DANGER
DANGER
explosion.
Switch on the main battery switch 15.

Switch temperature selection to stage 0=“cold”.
Press button 144.
Result:
– Engine preheating flow switches on and runs for approx. 10 to 25 seconds.
– Engine preheating starts after 10 to 25 seconds.
– Engine preheating runs in automatically adjustable mode.
6.01 LIEBHERR 853

B198440
854 LIEBHERR 6.01

1.3.2 Turning off

Once the preheating period is over:
Press button 144.
Result:
– The function control on button 144 goes out.
– Engine preheating is completed.
– The engine preheating will track for up to 150 seconds.
1.3.3 Starting up with preselect clock*

You can find a full description of the preselect clock* 29 in the provided manufacturer's operating
instructions.
Before turning off the engine, switch the temperature selection to level 0=“cold”.
Use the preselect clock* 29 to turn on the engine preheating.
Result:
1.3.4 Turning off with preselect clock*

Turn off the preselect clock* 29.
Result:
6.01 LIEBHERR 855

B198440
856 LIEBHERR 6.01

1.4 Air conditioning system* operation

The cab can be air conditioned.
You can find a full description of the air conditioning system in the manufacturer's accompanying
The air conditioning system* can be operated independently from the auxiliary heating*.
Carry out maintenance work on the air conditioning system* in accordance with the manufacturer's
1.4.1 Starting up
– the main battery switch is switched on
Close driver cab doors and windows.
If the temperature of the emitted air is too low, then it can be regulated by turning the heater on.
Set temperature by using button 146 at stage 0=“cold”.
Result:
– The display unit 114 displays the temperature level set.
Adjust the fan speed using the button 147 or set the button 148 to at least level 1.
Result:
– The display unit 114 displays the selected fan speed.
Turn on the air conditioning system using the button 152.

Result:
If you wish to change the air conditioning system's cooling capacity:

Press air recirculation button 153, “ventilator faster” button 147 or “ventilator slower” button 148.
6.01 LIEBHERR 857

B198441
858 LIEBHERR 6.01

2 Heating the crane operator's cab

The cab can be heated using three independent types of heating:
– engine-dependent heating
– engine-independent auxiliary heating with engine preheating, at outside temperature of up to -40
°C, WEBASTO; Thermo 90 S*
– engine-independent auxiliary heating with engine preheating, at outside temperature of less than
-40 °C, WEBASTO; DBW 2020*, Air Top 5000*
Individual adjustment of the heating (for both engine-dependent and engine-independent auxiliary
heating*) is carried out using the operating elements beneath the crane operator's seat and using the
switches and control lights on the instrument panel.
CAUTION
Risk of damage to the heating control units* when carrying out electrical welding operations on the
crane!
Remove the negative and positive cables from the vehicle and crane superstructure batteries and
apply the positive cable respectively to the vehicle earth.
2.1 Heater operation
2.1.1 Adjusting the temperature

The cab is heated using the engine coolant.
Adjust the control valve 310.
2.1.2 Adjusting the ventilation

Set 3-level fan switch 309.
Result:
– Air volume will be regulated.
2.1.3 Adjusting the recirculated air/fresh air

Operate changeover switch 308.
6.01 LIEBHERR 859

B198441
860 LIEBHERR 6.01

2.2 Operating engine-independent auxiliary heating*

The engine-independent auxiliary heating is used to heat the cab when the engine is turned off and as
auxiliary heating* at low ambient temperatures if the engine-dependent heating is insufficient.
You can find a full description of the auxiliary heating* in the manufacturer's accompanying operating
instructions.
During the summer, run the auxiliary heating* once a month for approx. 15 to 20 minutes.
Carry out maintenance work on the auxiliary heating* in accordance with the manufacturer's
2.2.1 Starting up
CAUTION
chart.
DANGER
DANGER
explosion.
Set control valve 310 at “warm”.

Press switch 356.
Result:
– The function control on switch 356 lights up.
2.2.2 Turning off

Press switch 356.
Result:
– The function control on switch 356 goes out.
– Each time the auxiliary heating is turned off, tracking takes place for up to 150 seconds.
CAUTION
– Once tracking is completed:

the control light 355 goes out.
6.01 LIEBHERR 861

B198441
862 LIEBHERR 6.01

2.2.3 Operation with preselect clock*

You can find a full description of the preselect clock 372 in the provided manufacturer's operating
instructions.
Set the required switch-on time, temperature and duration of the heating operation on the
preselect clock 372.
Open or close the air vent as desired.
Result:
– Upwards or downwards air distribution will be selected.
2.2.4 Operating thermostat*

– the control valve 310 is set to “warm”
Turn the thermostat 321 to the desired temperature.
2.2.5 Venting the system

When draining off the engine coolant, the contents of the heating system will also be drained because
the engine and heating operate as one circuit. When refilling, the system should be carefully
deaerated.
Fill the coolant above the equalizing reservoir of the engine cooling circuit in accordance with the
lubricant chart.
Start the engine as described in Chapter 3.04.
Result:
– The engine is deaerated as soon as no more air bubbles occur.
Once no more air bubbles appear in the equalizing reservoir:

Set control valve 310 at “cold”.
Result:
– The heating circuit will be deaerated.

Result:
– The heating circuit is deaerated as soon as no more air bubbles occur.
6.01 LIEBHERR 863

B198441
864 LIEBHERR 6.01

2.3 Operating engine-independent auxiliary heating for engine

pre-heating*
At ambient temperatures of under -20 °C, the crane engine must be preheated using engine
preheating which is operated with diesel fuel.
You can find a full description of the engine preheating in the manufacturer's accompanying operating
instructions.
2.3.1 Starting up
CAUTION
chart.
DANGER
DANGER
explosion.

Press switch 356.
Result:
– Engine preheating is turned on.
2.3.2 Turning off

Press switch 356.
Result:
– The control light 355 goes out.
CAUTION
6.01 LIEBHERR 865

B198441
866 LIEBHERR 6.01

2.3.3 Starting up with preselect clock*

You can find a full description of the preselect clock* 372 in the provided manufacturer's operating
instructions.
Use the preselect clock* 372 to turn on the engine preheating.
Result:
2.3.4 Turning off with preselect clock*

Turn off the preselect clock* 372.
Result:
6.01 LIEBHERR 867

B198441
868 LIEBHERR 6.01

2.4 Air conditioning system* operation

You can find a full description of the air conditioning system* in the provided manufacturer's operating
instructions.
Carry out maintenance work on the air conditioning system* in accordance with the manufacturer's
2.4.1 Starting up
– the main battery switch is switched on
– the air intake opening for recirculated air operation is clear
Open or close the air vent as desired.
Result:
– Upwards or downwards air distribution will be selected.
Close both windows and the cab door.

Set the changeover switch 308 for fresh air/recirculated air to recirculated air operation.
Press switch 354.
Result:
– Air conditioning system* is turned on and ready to operate.
Open the appropriate air vent for upwards air distribution.

Switch on fan using the rotary switch 309.
Adjust temperature by using the control valve 310.
6.01 LIEBHERR 869

026726-01 6.04 Sliding beam monitoring
B199956
870 LIEBHERR 6.04

6.04 Sliding beam monitoring 026726-01
1 General
The LICCON sliding beam monitoring checks the information entered by the crane driver with regard
to the support basis when selecting the load chart on the monitor.
Note
The sliding beam monitoring does not monitor the correct support of the crane and the pinning of
the sliding beams at the positions for which they have been constructed.
The sliding beams must be pinned at the “wide”, “reduced” or “retracted” pinning points and
secured.
2 Support bases
This crane can be operated on 3 different support bases. The length of the support bases is
unchangeable at 8.89 m and results from the vehicle length. The width of the support bases can be
set according to the load chart for “retracted”, “reduced” or “wide” configurations:
Support base
Wide 8.3 m
Reduced 5.5 m
Retracted 2.7 m
2.1 Setting the support bases

The support bases have no tolerances. The sliding beams must be pinned onto these support bases.
WARNING
If the following conditions are not met, the crane can topple over and cause fatal injuries!
All sliding beams must be pinned to preclude any subsequent movement of the support surfaces!
All retaining pins must be inserted and locked!
Only the support bases specified in the load chart may be used!
Intermediate positions are prohibited!
Pin and secure the sliding beams.
6.04 LIEBHERR 871

B199958
872 LIEBHERR 6.04

3 Working with sliding beam monitoring
3.1 Preparing the crane

Extend the sliding beams to the required width for crane use.
Pin and secure the sliding beams.
Support the crane.
Enter and confirm the load chart on the monitor.
If the selected load chart corresponds with the support base detected by the sliding beam
monitoring:
Result:
– The display on the monitor changes to the operating screen and the crane is ready for use.
3.2 Sliding beam monitoring function and error display
3.2.1 When entering the load chart

See separate error list and “diagnostics”.
Confirm the entered configuration status with function key F8 8.
Troubleshooting
If the monitor display does not change over to the operating screen:
The configuration status does not correspond with the load chart, e.g. for a “wide” support base, a
load chart with a “reduced” support base has been selected. The “OK” icon then changes to the
“Horn” icon. In the “Horn” icon an error code is displayed, illustration 1.
Check the configuration status.
See Chapter 4.02 “LICCON computer system”.
For example, if the error determination display indicates a sliding beam length error:
Select the load chart which corresponds to the sliding beam lengths.
or
Extend the sliding beams in accordance with the load chart preselected.
6.04 LIEBHERR 873

B199958
874 LIEBHERR 6.04

3.2.2 In the crane operation

If a valid load chart has been used, the crane may be operated while observing the relevant
guidelines provided in the operating instructions and the load charts.
Monitoring sliding beam lengths
The position of the sliding beams is continually monitored during crane operation and compared with
the selected load chart. An error code will be displayed in the “Horn” icon if any differences are
detected, illustration 2.
– The LICCON overload protection goes to overload.
– It is only possible to work using the bridging options of the LICCON overload protection.
– The slewing gear will be switched to non-operative.
– Starting is only possible in “Assembly”.
– The slewing gear will also shut down during slewing.
Sliding beam monitoring

In addition to the sliding beam lengths, the support forces are also monitored during sliding beam
monitoring. The system continually checks whether the total support force exceed the minimum crane
weight excluding equipment.
If this is not the case an error code is displayed, illustration 3.
– The LICCON overload protection goes to overload.
– It is only possible to work using the bridging options of the LICCON overload protection.
– The slewing gear will be switched to non-operative.
– Starting is only possible in “Assembly”.
Note
The slewing gear does not shut down during slewing.
The support forces have no effect on the setting of the load chart in the configuration program.
6.04 LIEBHERR 875

B199957
876 LIEBHERR 6.04

3.3 Method of operation of sliding beam monitoring

Sliding beam monitoring measures the length of the individual sliding beams and checks whether
these lay within the prescribed permissible ranges. If at least one sliding beam is not within this range
it is not possible to structure a load chart in the configuration program.
DANGER
Only support and operate the crane at the prescribed sliding beam lengths.
All sliding beams are extended to permissible but different positions.
Support base Position number

Wide 3
Reduced 2
Retracted 1
The lowest position number (see illustration 4) determines the permitted support base and the
resulting load chart.
If a sliding beam is located between two permissible positions (see illustration 5) no support base can
be assigned. Question marks are displayed in the “Support” icon.
Extend or retract the sliding beam to the defined position.
Pin and secure the sliding beam.
3.4 Procedure to follow in case of an error

It is imperative to distinguish between the following errors:
– Operating errors
– Sensor fault
– Total sensor failure
Error description:
– Operating errors are caused by the crane driver.
– A sensor fault may have occurred if the signal lies within a permissible measuring range but the
signal is incorrect. A sensor fault can however also be caused by (for example) an incorrect length
entry if the length sensor rope of the sliding beam has become tangled in the sliding beam box.
Disconnecting the sensor input will simulate the “sliding beam retracted” condition. The crane can,
but may not be operated in this condition.
– A total sensor failure will be detected by the sliding beam monitoring. The sliding beam
monitoring considers a total sensor failure to be equivalent to the sliding beam
“retracted” condition. The crane can, but may not be operated in this condition.
6.04 LIEBHERR 877

026723-00 6.05 Emergency take-down
B199953
878 LIEBHERR 6.05

6.05 Emergency take-down 026723-00
1 Emergency operation
In order to be able to strip down the crane in the event of a failure in the crane's hydraulic or electrical
systems or engine, ball valves and a hand lever 12 are attached to the superstructure. The ball valves
can be used to preselect the crane movement and this movement can be executed by moving the
hand lever 12.
1.1 General
DANGER
Increased risk of accident during emergency operation!
The crane movements are no longer monitored by LICCON in emergency operation.
Observe all notes and risk information described in Chapter 6.02.
Emergency operation and particularly derricking of the telescopic boom may only be carried out in
accordance with the information in the load chart.
Set down the load first if possible.
– For normal “crane operation”, turn the ball valves downwards.

– For “emergency operations”, turn the related ball valves (see following section and emergency
operation tag on the crane superstructure) upwards.
– Several movements cannot be carried out at the same time.
– All crane movements must be executed slowly and with great care.
– The ball valves must always be fully turned into the correct switching position.
1.2 Ball valve positions during emergency operations
1.2.1 Turning the rotating platform toward the left

Switch ball valve 1, ball valve 3 and ball valve 5 upward.
Turn ball valve 4 downwards.
1.2.2 Rotating the revolving platform to the right

Turn ball valve 1, ball valve 3 and ball valve 4 upwards.
Turn ball valve 5 downwards.
1.2.3 Raising the telescopic boom

Turn ball valve 6 upwards.
1.2.4 Lowering the telescopic boom

Turn ball valve 2 upwards.
6.05 LIEBHERR 879

026723-00 6.05 Emergency take-down
B199953
880 LIEBHERR 6.05

6.05 Emergency take-down 026723-00
1.2.5 Lifting the hoisting gear

Switch ball valve 7, ball valve 10 and ball valve 11.
Turn ball valve 8 and ball valve 9 downwards.
1.2.6 Lowering the hoisting gear

Switch ball valve 8, ball valve 9 and ball valve 11.
Turn ball valve 7 and ball valve 10 downwards.
1.3 Emergency operation with the drive motor

In cranes with two engines (crane motor and drive motor), the superstructure can be supplied with
power using the drive motor and a hydraulic transformer 14.
1.3.1 Preparing the crane for emegency operation

Remove the dummy plugs on the hydraulic connections.
The different diameters of the hydraulic lines prevent incorrect piping.

Connect the hydraulic connections from the chassis to the transformer 14.
Connect the hydraulic connections from the transformer 14 to the superstructure.
Switch the ball valve 13 to emergency operation.
1.3.2 Emergency operation

Run drive motor at a maximum speed of 1100 min-1 during emergency operations.
Start drive motor.
Refer to the previous section or to the emergency operations tag on the crane superstructure to
select the ball valves (1 - 11) for the appropriate crane movement.
Moving the hand lever 12 determines the speed of the each crane movement.
Operate the hand lever 12 and carry out the relevant crane movement carefully.
1.3.3 Completing emergency operation
DANGER
Risk of accident!
Following the “emergency operation”, always turn the ball valves to “crane operation”.
Switch all ball valves to “crane operation”.

Switch off the drive motor.
Disconnect the hydraulic lines and bolt with dummy plugs.
6.05 LIEBHERR 881

028368-00 6.07 Emergency operation of support
B110959
882 LIEBHERR 6.07

6.07 Emergency operation of support 028368-00
1 Emergency operation of support
1.1 Can the support cylinders or sliding beams no longer be actuated?

In the event that the electrical controls of the directional valve for the support should fail, these can be
manually retracted and extended by pressing in the magnetic piston on the corresponding directional
valve. The pressure stage must also be preselected.
As soon as the pressure on the magnetic piston is removed, the movement carried out stops.
To ensure the emergency operation of the sliding beams and the support, the valve -Y5 must be
manually actuated. For this purpose, a special “cap” is required, which is installed on the solenoid of
the valve -Y5. The sliding beams as well as the supports can now only be retracted or extended by
manually actuating the corresponding valves.
WARNING
Danger of fatal injury when extending and retracting the sliding beams!
The operator must monitor the extending and retracting of the sliding beams.
Ensure that there are no persons or objects in the danger zone when the sliding beams are being
extended and retracted.

– The engine is running.
– The hydraulic system is operative.
– The valve -Y5 is activated.
1.1.1 Functional block diagram Retract the support cylinders
Support cylinder Valve Side

Left front (3) -Y81 B
Left rear (4) -Y83 B
Right front (2) -Y85 B
Right rear (1) -Y87 B
1.1.2 Functional block diagram Extend the support cylinders
Support cylinder Valve Side

Left front (3) -Y81 A
Left rear (4) -Y83 A
Right front (2) -Y85 A
Right rear (1) -Y87 A
6.07 LIEBHERR 883

028368-00 6.07 Emergency operation of support
B110959
884 LIEBHERR 6.07

6.07 Emergency operation of support 028368-00
1.1.3 Functional block diagram Retract the sliding beams
Sliding beam Valve Side

Left front (3) -Y80 A
Left rear (4) -Y82 A
Right front (2) -Y84 A
Right rear (1) -Y86 A
1.1.4 Functional block diagram Extend the sliding beams
Sliding beam Valve Side

Left front (3) -Y80 B
Left rear (4) -Y82 B
Right front (2) -Y84 B
Right rear (1) -Y86 B
6.07 LIEBHERR 885

886 LIEBHERR
7.00 Service and maintenance
LIEBHERR 887
021681-15 7.01 Maintenance and service - General
B195219
888 LIEBHERR 7.01

7.01 Maintenance and service - General 021681-15
1 General
WARNING
Danger of fatal injury due to damaged crane components!
If crane components, which were damaged, for example due to maintenance errors, are not replaced
immediately, personnel can be fatally injured!
Maintain mobile crane components according to the data in the maintenance intervals, the
maintenance notes and the lubrication chart!
Replace damaged crane components immediately!
NOTICE
Damage of crane components!
If mobile crane components are not maintained according to the maintenance intervals and
maintenance guidelines in the individual chapter, or if other lubricants are used than specified in the
lubrication chart, the respective crane components can be damaged and/or functionally fail!
The warranty for the respective crane components are voided!
Maintain mobile crane components according to the data in the maintenance intervals, the
maintenance notes and the lubrication chart!
1.1 Liebherr Customer Service is for you

Liebherr mobile cranes - whether truck-mounted, mobile or crawler cranes - are technically advanced
products, which demonstrate daily crane use, even under tough conditions.
The high technical standards of these cranes provide functional security, offer functional security,
resistance to failure and ease of maintenance.
Liebherr is continuously developing the drive and control components. The combination of well proven
units and modern manufacturing methods produces cranes that are safe to operate and easy to
maintain.
Several hundred cranes are built every year for the international market, supported by international
service.
Liebherr's “After Sales Service” plays an important role in ensuring operational readiness and high
crane availability.
With Liebherr, service begins when the crane is handed over. Your crane operators will be
professionally trained in line with their level of knowledge, and we devote much time to this.
We also train your workshop staff in all crane-specific matters, because we know that they can deal
with more than just minor repairs themselves. Often there are specialists who can quickly and reliably
carry out crane repairs.
We also have specialist service advisers who can help you to fix your on-site problems creatively.
This contact by telephone saves time and money. In the event of problems, get in touch as soon as
possible.
Our service technicians are also specialists with years of experience, and can be deployed from local
support points. Naturally these experts have specialized knowledge and special tools.
But before you call on these people, it is worth making full use of the facilities for getting advice
mentioned above.
Note
Customers claims for warranties and refunds!
The buyer only has a claim to warranties and possible refund if only Original Liebherr replacement
parts, Liebherr service items and Liebherr lubricants are used for Liebherr cranes.
Only original Liebherr replacement parts have been tested for crane operational use, and may be
used without risking safety!
7.01 LIEBHERR 889

Note
Exclusion of liability!
In the event that replacement parts are used that are not Original Liebherr replacement parts and
not Original Liebherr service items and lubricants, Liebherr-Werk Ehingen GmbH disclaims all liability
for system functionality as well as for the components!
Only use Original Liebherr replacement parts!
1.2 Checking the battery voltage

Note
The battery voltage must be checked in regular intervals and recharged, if necessary! Especially if
a crane is taken “out of service” and a user, such as the airplane warning light is turned on.
1.3 Checking the antislip coverings

Check the antislip coverings regularly regarding their antislip properties and cleanliness. Clean antislip
coverings regularly with a strong brush to retain the antislip properties. To clean the surfaces, use a
commercially available cleaner and flush with water.
WARNING
Risk of falling!
If the following measures are not observed, personnel can fall down and be killed or severely injured!
Keep antislip coverings clean and free of snow and ice!
Only step on antislip coverings with clean shoes!
Replace or renew missing or damaged antislip coverings!
2 Cleaning and care of the crane

2.1 Instructions for sound damping (soundproofing)
Sound damping in the area of engines and other noise sources is an integral part of construction. It is
your task to limit the noise generation of vehicles and the sound level in the workplace to the legally
specified values in connection with sound absorption and the design of the equipment. They are
therefore an integral part for the construction permits for the machines. They may not be removed,
and if damaged, they must be replaced by original Liebherr replacement parts.
They have been designed to be "maintenance-free". They have been equipped with surfaces that
repel dirt, oil and water. They are fire-resistant and some of them are fireproof, depending on the
location.
For these reasons, these parts need minimal care. Any small dirt deposits can be disregarded, as the
acoustic effectiveness of the parts is not reduced.
NOTICE
Sound damping (soundproofing) damage!
By using unsuitable tools or cleaning methods, sound damping can be destroyed or damaged during
cleaning!
Remove severe contamination with suitable tools, for example with soft plastic scrapers!
Do not use tools with sharp edges!
Only use steam cleaners with extreme care and with a sufficient distance for sound damping and
low water pressure!
Do not use solvents for cleaning!
890 LIEBHERR 7.01

WARNING
Impurities from solvents or foreign substances!
For example, if sound damping is polluted by solvents, motor oils, gear oils, hydraulic oils or fuels,
such substances can ignite and significantly detrimentally change the fire performance of the sound
damping!
If such soiling of the sound damping occurs, remove immediately and replace with original
parts!
2.2 Care instructions for the cab and the crane operator's cabin
Note
The steering wheel, centre console, dashboard cover, floor cover, and dirty upholstery in the
driver's cab and the crane operator's cab should only be cleaned with warm water mixed with
dishwashing detergent!
Do not use any scouring agents!
3 Measures taken upon work interruption or transport

3.1 Hydraulic cylinder
NOTICE
Corrosion danger to the hydraulic cylinders!
When using cranes under aggressive environmental conditions, for example at places with maritime
climates and particularly salty air, hydraulic cylinders can corrode and thereby be destroyed or
severely damaged!
Expensive and extensive repairs can result!
If the crane is out of order for an extended period: Dismantle the crane!
Fully retract all crane hydraulic cylinders! If the hydraulic cylinders can not be completely retracted,
protect exposed areas of the piston rod from corrosion, for example by greasing!
Carefully grease particularly free areas on the piston rods, for example on luffing cylinders and
ballasting cylinders!
4 Maintenance work on the crane superstructure or

boom
WARNING
Risk of falling!
During maintenance work on the crane superstructure or boom, personnel must be secured with
appropriate safety measures to prevent them from falling! If this is not observed, working personnel
can fall and be killed or severely injured!
For all work on the crane where there is a danger of falling, suitable safety measures must be
taken!
The crane superstructure or boom may not be accessed without suitable aids!
Suitable aids are, for example: Lifting platforms, scaffoldings, ladders, assembly platforms,
auxiliary crane.
7.01 LIEBHERR 891

If railing are present on the crane superstructure, then they must be swung into operating position
and secured for all work, see crane operating instructions, chapter 2.06!
If the work cannot be carried out with such aids nor from the ground, then the maintenance
personnel must secure themselves with approved fall arrest systems to avoid falling, see Crane
It is prohibited to step on the driver's cab or cab roof and specially marked surfaces, see Crane
5 Maintenance and inspection guidelines

Note
The maintenance and inspection work on the crane chassis are carried out according to operating
hours or by kilometres travelled!
The maintenance and inspection work on the crane superstructure are carried out entirely
according to operating hours!
Observe the following chapters when performing maintenance and inspection of the crane:
– Chapter 7.02: Maintenance intervals - Crane chassis 1
– Chapter 7.03: Maintenance intervals - Crane superstructure 1
– Chapter 7.04: Maintenance guidelines - Crane chassis 2
– Chapter 7.05: Maintenance guidelines - Crane superstructure 2
– Chapter 7.06: Fill quantities, lubrication chart
– Chapter 7.07: Service items and lubricants
1 These chapters contain a list of service intervals for all maintenance work. Only the relevant work
is to be carried out.
2 For individual components, the manufacturer's specifications must be observed.
WARNING
Danger of accidents during maintenance and inspection of crane components!
During maintenance and inspection work on crane components, there exists increased danger of
accidents upon failure to observe maintenance and inspection guidelines!
Observe and adhere to the following listed warning notes and the generally applicable safety
rules!
5.1 Warning notes

– Maintenance work may only be carried out by authorized and especially trained technical
personnel.
– Unauthorized personnel are strictly prohibited from standing in the danger zone.
– Turn the engine off in the crane superstructure and the crane chassis.
– Apply the parking brake for the crane chassis.
– Pull the ignition key on the crane superstructure and the crane chassis and hand it to an
authorized person.
– Carrying out maintenance or inspection work during travel or crane operation are strictly
prohibited.
892 LIEBHERR 7.01

5.1.1 Warning notes on risk of burns
WARNING
Risk of burns during maintenance or inspection work!
While carrying out maintenance or inspection work, you can get severe burns on hot surfaces of the
crane components! This applies especially for the exhaust system or the travel gear!
Let any components to be maintained or inspected cool off!
Do not spill any service fluids over the hot components!
Avoid short circuits in the electrical system, especially on the battery!
5.1.2 Warning notes regarding turning parts
WARNING
Risk from turning parts!
If inspection work must be carried out while the engine is running, there is an increasing danger from
turning parts and from the ignition system!
Personnel can be severely injured!
Be particularly careful and do not grab into turning parts!
Never reach into the cooler fan when the engine is warm! The cooler fan could turn on suddenly!
5.1.3 Warning notes on scalding risk
WARNING
Risk of scalding during maintenance or inspection work!
Upon opening the coolant reservoir, hot coolant can escape explosively!
The most severe scalding on the entire body can result!
Never open the cap on the coolant reservoir as long as the engine is warm!
The cooling system is under pressure!
To protect face, hands and arms from hot steam of hot coolant, cover the cap with a large rag
when opening!
5.1.4 Warning notes on fire danger
DANGER
Danger of fire!
While working on fuel systems or on electrical systems, there exists an increased danger of fire upon
disregarding general safety rules!
This can result in increased property damage!
Disconnect the battery from the power supply!
Do not smoke!
Do not work near open flames!
Keep a functioning fire extinguisher ready!
7.01 LIEBHERR 893

5.1.5 Improper maintenance
NOTICE
Damage of components!
In case of incorrect maintenance, severe functional defects and damage on the components can
occur!
Add correct and sufficient service fluids during maintenance!
For all maintenance work, observe utmost cleanliness to prevent dirt from entering the inside of
the components!
Check components in regular intervals for leaks!
Have leaking components sealed immediately and properly!
894 LIEBHERR 7.01

7.02 Maintenance intervals - Crane chassis 026282-11
blank page!
7.02 LIEBHERR 895

026282-11 7.02 Maintenance intervals - Crane chassis
B195219
896 LIEBHERR 7.02

1 Crane chassis maintenance and inspection

schedule
First Regular maintenance, Mini- Checks

main- every mum
te- main-
nance te-
nance
after 250 h 500 h 1000 h annu- daily weekly
ally
5000 10000 20000
km km km
Diesel engine
Check oil level X
For all other maintenance tasks,
follow the instructions of the en-
gine manufacturer
Check the coolant level in the X
equalising reservoir
Replace coolant Every 2
years
Air filter
Check monitoring device X
Clean or change (follow the
instructions of the engine manu-
facturer)
Receptacle frame telescoping boom
Lubricate X
Hydraulic system
Check hydraulic system for leaks X
Check hydraulic tank oil level X
Check hydraulic oil, required de- 500 h X X
gree of purity: 20/18/15 (take oil
sample and have it checked by
oil supplier)
Replace bleeder filter of hydraulic 100 h X
tank
7.02 LIEBHERR 897


main- every mum
te- main-
nance te-
nance
ally
5000 10000 20000
km km km
Return filter 100 h X
Replace oil filter insert 100 h X
Check hydraulic pressure, X
readjust, if necessary
Hydraulic hose lines
Check for leaks and damage X
A safety check should be per- X
formed by experts
Steering
Check that steering gear and tie X
rods are firmly attached, check
cotter pin
Check hydraulic steering system X
for leaks
Check hydraulic hoses for leaks X
and damage
Check axle alignment, readjust, if X1
necessary
Replace pressure filter insert 100 h X
Check hydraulic steering stop, X
adjust if necessary
Check steering using test pro- X
gram
Hydraulic fan
Replace pressure filter insert of 100 h X
hydraulic fan
Hydraulic supports
Check ease of movement of X
sliding beams / grease
Check sliding beam cables X
898 LIEBHERR 7.02


main- every mum
te- main-
nance te-
nance
ally
5000 10000 20000
km km km
Grease sliding beam cylinder X
mounting pins
Lubricate bearing points of the X
swingable swing beams (folding
beams)
Check sight gauge, readjust if X
necessary
Axle suspension
Function test as blocking cylinder X
Check pressure accumulator pre- X4 X4
tension pressure (nitrogen)
Automatic transmission
Check oil level X
Check oil pressure X
Check operating temperature X
Check for leaks X
Check or tighten mounting X
screws
Oil change 100 h X X
Replace oil filter 100 h X X
Powershift transmission
Check oil level X
Check for leaks X
Replace oil filter 100 h X X
Automatic gear box AS-Tronic, AS-Tronic HD
Check oil level X
Check for leaks X
Oil change Every 3
years5
7.02 LIEBHERR 899


main- every mum
te- main-
nance te-
nance
ally
5000 10000 20000
km km km
Replace oil filter Every 3
years5
Torque converter transmission TC 2
Check oil level X
Oil change X
Replace oil filter X
Torque converter transmission TC HD
Check oil level X
Oil change X
Replace suction filter X
Replace pressure filter X
Displacement gear
Check for leaks X
Check mounting X
Oil change 1000 X X
km
Distributor gear
Oil change 1000 X X
km
Check oil level X
Check for leaks X
Check or tighten mounting X
screws
Check on road gear / off road X
gear transfer function
Check all-wheel drive enabling X
function
Have tachograph / trip recorder Every 2
checked years
Clean breather nipple X X
900 LIEBHERR 7.02


main- every mum
te- main-
nance te-
nance
ally
5000 10000 20000
km km km
Hydrostatic travel drive
Check hydraulic hoses for leaks X
and damage
Clean filter unit 100 h X
Replace filter unit X
Pump distributor gear
Check for leaks X
Check mounting X
Gear shafts and bearing block
Check flange bolts, retighten if 100 km 25000 Every 6
necessary km months
Visually check the gear shafts 25000 Every 6
km months
Visually check the intermediate 25000 Every 6
shaft bearing / bearing block km months
Lubricate gear bearings (if they 100000 Every 2
can be lubricated) km years
Lubricate length compensation (if 100000 Every 2
it can be lubricated) km years
Drive shafts between the engine and gearbox or gearbox and distributor gear
Caution: These checks should only be carried out by authorized and trained expert personnel!
Check resistance or play in joint 100000 Every 2
by manually bending it after km years
removal
Check length compensation for 100000 Every 2
impermissible bending play after km years
removal. Replace the drive shaft
if the bending play exceeds 0.17
mm .
7.02 LIEBHERR 901


main- every mum
te- main-
nance te-
nance
ally
5000 10000 20000
km km km
Axle, driven
Check for leaks X
Oil level checks at axle housing, X
differential housing and wheel
hubs
Grease steering knuckle bear- 10000 X
ings km
Check mounting X
Oil change 1000 X Every 2
km years
Replace wheel bearing grease Every 2
filling (if lubricated with grease) years
Clean breather nipple on axle X X
housing
Axles, non-driven
Grease steering knuckle bear- 10000 X
ings km
Check mounting X
Replace wheel hub grease filling X X
Adjust wheel bearings X X
Electrical system
Check vehicle lighting for func- X
tion
Check cable connections and X3
battery acid levels
Fuel system
Check for leaks X
Check condition and mounting X X
Drain off water and sediments X X
902 LIEBHERR 7.02


main- every mum
te- main-
nance te-
nance
ally
5000 10000 20000
km km km
Clean auxiliary fuel pump prelimi- X X
nary filter
Check fuel preliminary filter, drain Every
off water if necessary 50 h
Replace fuel preliminary filter X
Tires
Check for external damage X
Check the tire pressure X
Check tread wear and depth X
(observe governmental regula-
tions)
Ensure that lug nuts are tight, 100 km X
retighten if necessary
Brake system
Check brake system X
Check brake lining thickness X
Adjust brakes if necessary, re- X
place linings if required
Check the brake discs X
Check the brake drums X
Check function of parking brake X
and service brake
Eddy current brake
Check mechanical and electrical 5000 X
parts (follow manufacturer km
instructions)
Pressurized air system
Check for leaks X
Check operating pressure of X
brake system
7.02 LIEBHERR 903


main- every mum
te- main-
nance te-
nance
ally
5000 10000 20000
km km km
Check cut-off pressure X
Drain air pressure tank X
Replace air drier granular car- X
tridges
Clean air drier preliminary filter X
Driver's cab
Check armatures / instruments X
for function
Check indicator lights for function X
Check engine brake operation X
Check retarder operation X
Emergency control
Check for correct function X
Support pads with equalization
Replace grease filling X
Perform function test X
1 Every 500 km to 2000 km for frequent off-road driving.

2 At least 1x a year for frequent off-road driving.
3 In hot climates twice a year.
4 Note chapter 7.04, Maintenance guidelines - Crane chassis.
5 Only when using ZF-Ecofluid M, otherwise every 2 years.
904 LIEBHERR 7.02

7.03 Maintanance intervals - Crane superstructure 025011-15
blank page!
7.03 LIEBHERR 905

025011-15 7.03 Maintanance intervals - Crane superstructure
B195219
906 LIEBHERR 7.03

1 Crane superstructure maintenance and inspection

schedule
First Regular maintenance, every Mini- Checks

main- mum
te- main-
nance te-
nance
after 125 h 250 h 500 h 1500 h Annu- Daily Weekly
ally
Diesel engine
Check the oil level X
For all other maintenance
tasks, follow the instructions
of the engine manufacturer
Check the coolant level in the X
expansion tank
Replace coolant Every 2
years
Engine independent heater
Check the fluid level in the X
expansion tank
Change the fluid for the heat- Every 2
ing system years
Air filter
Check monitoring device X
Clean or change (follow the
instructions of the engine
manufacturer)
Rotary connection
Lubricate gearing X
Lubricate the rotary connec- X1
tion
Check screws for tight seating 250 h X X
Check tilt play X X
Rope winches
Check for leaks X
7.03 LIEBHERR 907


main- mum
te- main-
nance te-
nance
ally
Check the mounting screws 250 h X X
for tight seating
Check the condition of the oil X
in the oil reservoir
Oil change 3000 h Every 4
years
Check the remaining theoreti- X
cal utilization life by a tech-
nical expert
Check the remaining theoreti- Every 4
cal utilization life by autho- years
rized specialist
Hoist gear brake
Check for leaks X
years
Drive shafts
Check flange bolts X
Lubricate X X
Lattice sections
Check for cracks and damage X
Guy rods
Check for cracks, damage X
and distortion by a technical
expert
Check for cracks, damage Every 4
and distortion by an years
authorised inspector
Checking the retaining ele- X
ments
908 LIEBHERR 7.03


main- mum
te- main-
nance te-
nance
ally
Relapse supports
Lubricate bearings X X
Check the oscillation guard X2, 6
for easy movement
Relapse cylinder
Check for leaks X2, 6
Check pretension pressure X2, 6 X X
(nitrogen)
Check the oil quantity X2, 6 X X
Pneumatic springs
Check the function X2, 5, 6 X X
A-bracket
Lubricate bearing X
Check the lever for the limit X
switch on the A-frame 3 for
easy movement and reset of
spring
Check the rods with guide rail X
on the A-frame 2 and A-
frame 3 for easy movement
and distortion
Counterweight
Check tightening torque of 1,000 or X
mounting screws km 10,000
km
Ballasting
Press on pulleys of cable winches
Grease guides X X
Rope pulleys
Check for wear, damage, X X
cracks and easy movement
7.03 LIEBHERR 909


main- mum
te- main-
nance te-
nance
ally
Lubricate rope pulleys X X
Crane ropes
Visual inspection for cracks X
and deformation
Check by trained personnel, Month-
grease if necessary ly
Check by technical expert X
Check by authorised inspec- Every 4
tor years
Hook blocks
Grease hook X X
Check distance gap (y) X X
Crane cab
Check armatures / instru- X
ments for function
Check indicator lights for X
function
Replace filter insert water X
heater
Check fluid level in expansion X
tank of engine control
Crane cab, extendable or inclinable
Check for correct function X X
Overload protection
Check length sensor for func- X X
tion
Check length sensor rope for X X
damage
Electrical system
910 LIEBHERR 7.03


main- mum
te- main-
nance te-
nance
ally
Check cable connections and X3
battery acid levels
Fuel system
Check for leaks X
Check condition and mount- X
ing
Drain off water and sediments X
Slewing gear
Check for leaks X
for tight seating
years
Turntable locking mechanism
Check for correct function X X
Lubricate X X
Bearings
Checking the retaining ele- X
ments
Pump distributor gear
Check for leaks X
Hydraulic hose lines
Check for leaks and damage X
Check for safe condition by X
expert
Hydraulic system
Check for leaks X
7.03 LIEBHERR 911


main- mum
te- main-
nance te-
nance
ally
Replace servo pressure and 250 h X X
replenishing pressure filter in-
serts
Replace return filter inserts 250 h X X
(only for cranes with open
hydraulic circuit)
Replace bleeder filter of hy- 250 h X X
draulic tank
Check hydraulic oil, required 500 h X X
degree of purity: 20/18/15
(take oil sample and have it
checked by oil supplier)
Hydraulic cylinder
Check for leaks X
Hydraulic pressure accumulator (nitrogen)
Check pretension pressures X4 X4
Air pressure system
Check for leaks X
Check operating pressure X
Check shut off pressure X
Check operation of automatic X
drain valve
Replace air drier granule ele- X
ments
Clean air drier preliminary X
filter
Central lubrication system
Check the grease container X X
fill level
Emergency control
912 LIEBHERR 7.03


main- mum
te- main-
nance te-
nance
ally
Telescopic boom with cable mechanism
Check telescopic boom for X
distortions and cracks
Grease the sliding surfaces of X X
the telescopic boom bearing
Lubricate change over pulleys X X
of telescoping mechanism
Check mounting screws on X X
change over pulleys for tight
seating
Check cable mechanism, 250 h X
readjust, if necessary
Dismantle and check boom 20000 Every
h 10
years
Pneumatic boom lock
Clean air filter with com- X X
pressed air
Check locking pins X X
Lubricate locking pins X X
Telematik telescopic boom system
Check telescopic boom sys- X
tem for distortion, damage
and cracks
Check hydraulic components X
for leaks and damage
Check telescoping cylinder for X X
proper condition
Check pull knob retainer and X
mounting screws for tight
seating
7.03 LIEBHERR 913


main- mum
te- main-
nance te-
nance
ally
Check mounting screws of X
push out cylinder for tight
seating
Check twist guard of cylinder X
pinning and telescopic boom
pinning
Check push out rod for proper X X
condition
Check locking pins and lock- X X
ing bores for proper condition
Check inner and outer sliding X X
surfaces for proper condition
Lubricate sliding surfaces X5
Grease guide rails on tele- X5
scoping cylinder
Dismantle and check boom 20000 Every
h 10
years
Telescopic boom guying
Check for distortions and X
cracks
Lubricate grease fitting on the Every 3
TA / TY-guying months
5, 6
Check guy winch for leaks X

Check the oil level on the guy Every 6
winch months
for tight seating
Change the oil on the guy Every 4
winch years
Derrick ballast
914 LIEBHERR 7.03


main- mum
te- main-
nance te-
nance
ally
Check frame, suspension and X
guide section for distortion
and cracks
Check wheels for condition X
and tight seating
1 every 3 months if the crane is not moved

2 carry out a visual inspection before every start up
3 in hot climates 2x a year
4 note chapter 7.05, Crane superstructure maintenance instructions
5 and as necessary
6 during assembly
7.03 LIEBHERR 915

026697-02 7.04 Maintenance guidelines - Crane chassis
B198418
916 LIEBHERR 7.04

7.04 Maintenance guidelines - Crane chassis 026697-02
1 Diesel engine
Never step on fuel lines during maintenance or repair work in the engine area!
DANGER
Danger of fire!
Make sure that the engine area is kept free of diesel fuel.
Extreme cleanliness is vital, particularly during filter changes and bleeding. Wipe up any spilled
fuel!
When changing the filter it is advisable to place some cotton rags underneath to absorb the fuel
before removing the filter.
1.1 Engine oil
1.1.1 Checking the oil level

– The crane vehicle is in horizontal position.
– The diesel engine is turned off and the oil has collected in the oil pan.
Remove the dipstick 1 and wipe it off.
Reinsert the dipstick 1 and pull it out again.
The oil level must be between the min. and max. mark on the dipstick 1.
Check the oil level.
NOTICE
Danger of damaging the engine!
If the oil level has dropped below the minimum mark, add engine oil according to the lubrication chart
until the oil level is between the minimum and maximum marks!
Add engine oil and check again!
Reinsert the dipstick 1.
1.1.2 Changing the oil

Refer to separate operating instructions “LIEBHERR Diesel engines”.
7.04 LIEBHERR 917

B198419
918 LIEBHERR 7.04

1.2 Coolant Engine cooling

The coolant level on the expansion tank is monitored with a water level probe. If the coolant level is
too low, the warning light 182 “Engine coolant level too low” lights up on the display unit.
The coolant temperature of the travel motor can be read on the display unit on the bar chart via the
warning light 231.
WARNING
Danger of skin burns!
The diesel engine must be cold when checking the coolant.
Turn the cap on the filler neck of the water cooler expansion tank to the first notch.
Release excess pressure.
Remove the cap.
Add coolant as specified in the lubrication chart only on the filler neck of the water cooler expansion
tank.
Add coolant if required.
1.3 Air filter

The air filter is monitored electrically. If the vacuum in the intake pipe has increased because of dirty
air filter inserts, the warning light 183 in the driver's cab display unit lights up.
If the warning light 183 lights up:
Clean or replace the filter insert.
1.4 Diesel particle filter*

DANGER
Danger of igniting the diesel particle filter*!
The diesel particle filter* may only be regenerated under the supervision of operating personnel!
Carry out the operation and maintenance of the diesel particle filter* according to the separate
operating instructions of the diesel particle filter* manufacturer.
7.04 LIEBHERR 919

B198420
920 LIEBHERR 7.04

1.5 Fuel pre-filter
1.5.1 Draining the fuel pre-filter
Note
The water separator 2 on the fuel pre-filter must be drained at regular intervals.

Place a catch basin under the water separator.
Close the ball valve 1.
Open the drain valve 3 and drain water until fuel emerges.
Close the drain valve 3.
Open the ball valve 1.
Remove the catch basin and dispose of the fluid.
1.5.2 Cleaning the filter strainer
DANGER
Danger of fire and explosion!
Do not smoke!
Avoid open flames!
Work only when the diesel engine is turned off!
Maintain extreme cleanliness during all work!

Place a catch basin under the fuel pre-filter.
Close the ball valve 1.
Open the drain valve 3 until no more fuel emerges.
Remove the catch basin and dispose of the fluid.
Remove the screws 4 and remove the cover 8.
Remove the filter strainer 6 and clean it properly.
Insert the cleaned filter strainer 6 properly.
Properly install the cover 8 with seals.
Properly tighten the screws 4.
Open the ball valve 1.
Open the breather screw 5.
Operate the hand pump 7 and properly bleed the fuel filter.
Properly tighten the breather screw 5.
Start the engine and check the fuel pre-filter for leaks.
7.04 LIEBHERR 921

B199885
922 LIEBHERR 7.04

2 Automatic transmission
NOTICE
Danger of transmission damage!
Please maintain utmost cleanliness during all work to prevent any dirt from getting into the
transmission!
Check the transmission for leaks at regular intervals!
Have a leaking transmission sealed immediately and professionally!
2.1 Checking the oil level on the automatic transmission

– The crane is in horizontal position.
– The gear oil has cooled down (less than 40 ° C).
Remove the level control screw 1.
The oil level must reach the edge of the bore.

Perform a visual inspection.
If the level control screw 1 cannot be seen due to structural reasons, fluid must be added on the oil
filler plug 4 until fluid escapes on the level control screw 1.
NOTICE
Too little oil causes lubricating problems and reduces the service life of the transmission. Too much oil
causes more displacement work and therefore transmission overheating.
Add oil up to the overflow level of the level control screw 1, as specified in the lubricant chart and
re-check the level.
Reinstall the level control screw 1 with a new seal and tighten.
7.04 LIEBHERR 923

B199885
924 LIEBHERR 7.04

2.2 Replacing the oil in the automatic transmission

Note
Before changing the oil, do not slow down the vehicle with the intarder.

– The transmission is at operating temperature.
Remove the oil filler plug 4.
Remove the oil drain plug 2 and oil drain plug 3 and drain the oil.
Clean the magnets on the oil drain plugs.
Reinstall the oil drain plug 2 and the oil drain plug 3 with a new seal and tighten.
Add oil as specified in the lubrication chart on the oil filler plug 4 until it starts to overflow on the
level control screw 1.
After adding oil, reinstall the oil filler plug 4 and the level control screw 1 with new seal and tighten.
Test drive the vehicle.
Check the oil level and add oil if necessary.
2.3 Changing the fine filter

The fine filter 5 must be changed during every oil change. Ensure that no pollutants or oil sludge can
penetrate the circuit when changing the fine filter 5.
Unscrew the mounting screw for the fine filter.
Remove the old fine filter.
Properly install the new fine filter.
Screw in and tighten the mounting screw.
Test drive the vehicle without using the intarder.
Check the oil level and add oil if necessary.
7.04 LIEBHERR 925

B109814
926 LIEBHERR 7.04

3 Transfer gear box

Maintain utmost cleanliness during all work to prevent any dirt from entering the inside of the gear.
3.1 Checking the oil level

The oil level must be up to the edge of the hole for the level control screw 2.
NOTICE
If more than 0.5 l runs out on the bore edge of the level control screw 2, then this is a sign of a defect
in the oil circuit!
Contact the Service Dept. at Liebherrwerk Ehingen!
NOTICE
Too little oil causes lubricating problems and reduces the service life of the transmission. Too much oil
causes more displacement work and overheats the transmission!
Add oil up to the overflow level of the level control screw 2 as specified in the lubricant chart and
recheck the level!
Reinstall the level control screw 2 with a new seal and tighten.
7.04 LIEBHERR 927

B109814
928 LIEBHERR 7.04

3.2 Changing the oil

– The gear has warmed up.
Remove the oil filler plug 1 and the level control screw 2.
Remove the oil drain plug 3, drain the oil and determine the oil quantity.
Note
During removal, the check valves 4 must remain on the supply line 5 and the return line 6 on the
transfer gear box.
Remove the supply line 5 and the return line 6 on the transfer gear box, drain the oil and
determine the oil quantity.
If necessary:
Carefully blow out the oil lines with maximum 4 bar to drain all the oil.
Note
If the determined oil quantity is significantly less that the oil quantities specified in chapter 7.06,
then this is a sign that there is a leak in the oil circuit. Find the reason for the leaky oil circuit and
fix it.
Check the supply line 5 and the return line 6 for damage.
Install the supply line 5 and the return line 6 properly.
Install the oil drain plug 3 and the level control screw 2 with a new seal and tighten.
Add the complete oil quantity for the transfer gearbox with oil cooler and line as specified in the
lubrication chart on the oil filler plug 1. See chapter 7.06 and 7.07.
Install the oil filler plug 1 with a new seal and tighten.
Drive the mobile crane about 10 km.
Note
After about 10 km, the oil cooler is filled with oil.
Check the oil level as described in paragraph “Checking the oil level” and add more oil or drain oil,
as necessary.
7.04 LIEBHERR 929

B198422
930 LIEBHERR 7.04

4 Hydraulic system
Extreme cleanliness must be maintained when adding oil.
4.1 Hydraulic oil reservoir

– The support cylinders and sliding beams have been fully retracted.
– The vehicle has been lowered to the lowest axle suspension level.
DANGER
Danger of accident if hydraulic pump is damaged!
If the oil level is too low, the hydraulic pump may be damaged, which will increase the risk of accident
because of incapacity to steer. The cylinders cannot be fully extended and the vehicle cannot be
levelled.
Check oil level and add oil, if necessary.
The oil level must be in the center of the oil level sight gauge 1.
Check the oil level in the oil level sight gauge 1 of hydraulic oil tank.
Troubleshooting
No oil visible in the oil level sight gauge 1?
Add oil as specified in the lubricant chart using a fine-meshed filter until the oil level is visible in
center of oil level sight gauge 1.
4.1.2 Checking the aeration / bleeder filter

Open the cover with turn lock.
Check the filter 2 for impurities (visual inspection).
In the event of heavy contamination:
Replace the filter 2.
Close the cover with the turn lock again.
Start the diesel engine.
Slowly run through all crane movements.
Check the oil level again and add oil if necessary.
7.04 LIEBHERR 931

B198422
932 LIEBHERR 7.04

4.1.3 Checking and replacing the return filter

Change the return filters 3 according to the maintenance intervals in chapter 7.02.
If a return filter 3 is equipped with a maintenance indicator* 4 and the red bar display is visible when
the oil is at operating temperature, then the filter inserts in both return filters 3 must be changed.
Unscrew and remove both filter covers on the return filter 3.
Remove the filter units.
Rinse out the filter housing.
Clean the sealing surfaces on the covers and filter housings.
Insert new filter units.
Lubricate the rubber seal rings in the covers with oil.
Replace both filter covers and screw tight.
Start the diesel engine and check the filters for leaks.
Check the oil level again and add oil, if necessary.
4.1.4 Pressure filter

The pressure filters 5 are equipped with a maintenance indicator. If the red bar indicator is visible
when the oil is at operating temperature, then the filter cartridge must be replaced.
Release the filter cartridge and collect any escaping oil in a suitable container.
Remove and dispose of the filter cartridge.
Clean the sealing surface on the filter bracket.
Oil the rubber sealing ring on the new filter cartridge.
Install a new filter cartridge and tighten.
Start the engine and check for leaks.
Result:
– This bleeds the hydraulic system.
Check the oil level again and add oil, if necessary.
7.04 LIEBHERR 933

B199884
934 LIEBHERR 7.04

4.2 Diaphragm reservoirs of axle suspension / axle blocking system

Diaphragm reservoirs have been installed in the hydraulic system. The pretension pressures are
specified in the hydraulic circuit diagram as well as on the individual diaphragm reservoirs. The
pretension pressure must be measured separately in each diaphragm reservoir.
NOTICE
Risk of travel gear damage!
If the outside temperature fluctuates considerably, e.g. after transport to extremely hot or cold
countries or in countries with considerable differences between the summer and winter temperatures,
the gas accumulator pressures may change. Inadequate gas pretension may cause the reservoir
diaphragms to be overstressed. If the pretension is too high, the spring action in the axle suspension if
no longer guaranteed.
Check the gas accumulator pressures and correct if necessary.

– The axle suspension / axle blocking system is in the suspended position.
– The function control on button 130 does not light up.
Lower vehicle down as far as possible using button 119, button 120, button 135, button 136 and
enter 143 until the oil has drained from the diaphragm reservoirs.
DANGER
Risk of explosion!
The pressure in the nitrogen cylinder must be less than the maximum permitted operating pressure of
the reservoir or the pressure gauge. Otherwise install a pressure reducer between the cylinder and
the filling device.
Do not use air or oxygen to fill the diaphragm reservoir!
The pretension pressure in the hydraulic reservoirs may only be checked by an expert with
appropriate training and equipment. In addition, the national regulations for pressurized container
inspections must also be observed.
Check the pretension pressure with a testing and filling device and correct it, if necessary.
Press level button 129 and ENTER 143 until the function control on the level button 129 blinks.
Result:
– The vehicle is at the level setting for road driving.
4.3 Hydraulic hose lines

The hydraulic hose lines must be checked according to ISO 9927-1 by an experienced technician or
expert mechanic, as required, depending on the duration of use and the operating conditions, but at
least once a year.
Experienced technicians are persons who:
– possess sufficient knowledge about cranes due to their professional background and experience,
– are familiar with the relevant settings to detect any abnormal deviations,
– have undergone special training.
Expert mechanics are mechanics, who:
– are experienced in the design, construction or maintenance of cranes,
– possess sufficient knowledge about the relevant settings and standards,
– are fully equipped to perform inspections,
– are able to assess the safety condition of the crane,
– can decide which action needs to be taken to ensure the crane can continue to be operated
safely.
7.04 LIEBHERR 935

Note
The applicable national regulations must also be complied with!
4.3.1 Checking the hydraulic hose lines within area of responsibility of the German
employer's liability insurance associations
At least once a year, an expert must check whether the hydraulic hoses are in a safe condition. The
crane must be inspected by an authorized inspector every four years from the day it was first
licensed. After the 12th year of operation, the crane must be inspected annually by an authorized
inspector.
The expert or authorized inspector must document the fact that the hydraulic hoses can continue to
be used in the crane!
An expert is someone:
– whose technical training and experience means that he has adequate knowledge in the field of
hydraulic hoses and hose systems,
– who is familiar with the relevant occupational health and safety regulations,
– who is familiar with the relevant accident prevention guidelines,
– who is familiar with the directives and generally accepted technical regulations (e.g. DIN
standards, VDE regulations, technical regulations of other EU member states or other countries
that have signed the European Economic Community agreement),
– who can properly assess whether hydraulic hoses and hose systems are deemed safe in
accordance with the guidelines and regulations stated above.
An authorized inspector is :
– an authorized expert employed by the technical supervisory authorities,
– in Hamburg this is the Amt für Arbeitsschutz (office for occupational health and safety),
– in Hessen these are the technical supervisory agencies,
– an authorized expert appointed by the professional associations.
4.3.2 Examples of possible defects in hose lines
DANGER
Risk of fire or accident!
If problems are discovered during inspections, then they must be remedied immediately or suitable
measures are to be taken. Failure to do this can result in serious injury to persons, death or damage
to property.
Remedy problems or take suitable measures!
– Damage to the outer layer as far as the intermediate later (e.g. chafing, cuts and cracks)
– Outer layer brittleness (hose material cracking)
– Deformation that differs from the natural shape of the hose or hose system when depressurised or
pressurised or when the hose is bent (e.g. layer separation, bubbling, crushing or kinking)
– Leaks
– Failure to follow installation instructions
– Damage or deformation of hose fittings that inhibit the operation and strength of the fitting or the
hose / fitting connection
– Hose slipping out of fitting
– Fitting corrosion that inhibits function and strength
– Storage time or usage period exceeded
936 LIEBHERR 7.04

4.3.3 Maintaining hose lines

– We recommend to check all hoses, hose lines and screw fittings daily, but at least every two
weeks for leaks and externally recognizable signs of damage.
– Damaged parts must be replaced immediately! Oil spray can lead to injuries and fires.
– Hydraulic lines and hoses may not be repaired.
– Hoses that have already been used in a hose system may not be reinstalled in hose systems.
– Always use original LIEBHERR spare parts when replacing hoses and hose systems.
– Always ensure that the hoses are routed free of torsion. If high pressure hoses are being used,
attach screws of half clamps or full flange at both ends of hose and then tighten.
– When using high pressure hoses with a bent fitting, tighten the end with the bent fitting first when
tightening the flanges, then the end with the straight fitting.
– Any mounting clamps in the hose center may be attached and tightened only thereafter.
– Route the hoses in such a way that chafing with other hoses or other structures is prevented.
Maintain minimum clearance of approximately ½ the outer diameter of the hose from other parts.
The clearance must never be less than 10 mm - 15 mm.
7.04 LIEBHERR 937

B198423
938 LIEBHERR 7.04

4.3.4 Changing hose lines for active rear axle steering
DANGER
If the hose lines are not changed at proper intervals, personnel can be severely injured or killed. In
addition, property damage can occur on the crane.
Replace hose lines at appropriate intervals!
This must be documented in the crane's inspection log by the expert or the authorized inspector.
Note
Deviating from the data in section “Checking the hose lines within the area of responsibility of the
German employer's liability insurance associations”, the following replacement intervals apply for
hose lines for the active rear axle steering!
The service life of a hose line may not exceed six years, including a storage period of a maximum of
two years. (Pay attention to manufacturing date of hose). The duration of use can also be defined by
the expert or authorized inspector in accordance with existing test and experience data in the
individual application areas, taking the usage conditions into consideration.
Steering
DANGER
Impairment of steering!
Leaky hydraulic lines can impair the steering ability!
Damaged or leaking hydraulic hoses must be replaced immediately!
Check hydraulic hoses 2 from the steering centring cylinder 1 to control block of third, fourth and fifth
axles for cracks, damage and leaks.
7.04 LIEBHERR 939

B109771
940 LIEBHERR 7.04

5 Compressed air and brake system air dryer
5.1 Replacing the granular cartridge

CAUTION
Danger!
The granular cartridge of the air dryer 1 is under spring tension.
Caution when replacing the cartridge.
Replace granular cartridge once per year.
6 Tires / wheels
Note
See Crane operating instructions, chapter 8.01!
6.1 Checking the tires

While doing this, also check the spare tire*.
DANGER
Risk of accident!
Regularly check the tires for damage, depth of tread, foreign particles and tire pressure!
6.2 Changing the wheel

Note
See the Crane operating instructions, chapter 9.02!
7.04 LIEBHERR 941

B109772
942 LIEBHERR 7.04

7 Axles
Please maintain extreme cleanliness during all work to prevent dirt from entering the interior of the
axle casings.
7.1 Axle casings

The position of oil filler plug 1, oil filler plug 2 as well as the position of oil drain plug 3 and oil drain
plug 4 depends on the type of axle.

Remove the oil filler / control plug 1, see illustration 1.
Remove the oil filler plug 2, see illustration 2.

NOTICE
Damage to the axles!
If the oil level has dropped, add oil according to the lubrication chart until it runs over on the oil filler /
control plug 1 (illustration 1) or oil filler plug 2 (illustration 2)!
Add oil and check again!
Install the oil filler / control plug 1 with new seal ring and tighten, see illustration 1.
Install the oil filler plug 2 with new seal ring and tighten, see illustration 2.
7.1.2 Changing the oil (illustration 1)

Remove the oil filler / control plug 1.
Remove the oil drain plug 4 and drain the oil.
Install the oil drain plug 4 with new seal ring and tighten.
Add oil as specified in the lubrication chart on the oil filler / control plug 1 until it starts to overflow
at the edge of the bore for the oil filler / control plug 1.
Install the oil filler / control plug 1 with new seal ring and tighten.
7.1.3 Changing the oil (illustration 2)

Remove the oil filler plug 1 and the oil filler plug 2.
Reinstall the oil drain plug 4 with new seal ring and tighten.
Add oil as specified in the lubrication chart on the oil filler plug 1 or the oil filler plug 2 until it starts
to overflow on the bore edge of the oil filler plug 2.
Reinstall the oil filler plug 2 with new seal ring and tighten.
7.04 LIEBHERR 943

B109773
944 LIEBHERR 7.04

7.2 Wheel hubs

– The crane vehicle is supported.

Turn each driven wheel until the oil drain plug 5 reaches its lowest point and the line 4 is exactly
horizontal.

NOTICE
Danger of damage!
If the oil level has dropped, always top up with the oil specified in the lubrication chart up to the
overflow of the oil filler plug 3.
Add oil and check again.

Turn each driven wheel until the oil drain plug 5 reaches its lowest point and the line 4 is exactly
horizontal.
Add oil as specified in the lubricant chart on the oil filler plug 3 until it starts to overflow at the edge
of the bore.
8 Wheel alignment
8.1 Checking the wheel alignment
The wheel alignment must be checked at regular intervals. Failure to perform this check can result in
increased tire wear. If extremely high stress has occurred such as driving against curbs, it is
extremely important to check the wheel alignment.
Always have the wheel alignment checked by a trained and authorized expert.
7.04 LIEBHERR 945

B109852
946 LIEBHERR 7.04

9 Tilting the driver's cab

The driver's cab can be tilted forward for assembly or disassembly purposes to max. 24°.
Note
Depending on the version, the support rod 1 is carried along on front on the bumper, see
point P1 or behind the driver's cab, see point P2!
9.1 Measures before tilting

Before the driver's cab may be tilted forward over the front bearing, the following measures must be
taken, depending on the version.
Mark the position of drive shaft in relation to the miter gear.
Unscrew the drive shaft from the miter gear to the steering gear on the flange.
Remove the shock absorbers and stabilisers (if necessary) from rear wall of driver's cab.
Pay attention to cables and hoses on underside of driver's cab.

Loosen any mountings, if necessary.
WARNING
Risk of accident if driver's cab tilts forward in an uncontrolled manner!
The maximum angle that the driver's cab may be tilted forward is 24°.
The driver's cab must be properly supported in the tilted position and secured with a support rod 1.
Screw and secure the support rod 1 with a nut M10 2 and washer on top on the driver's cab.
Bolt the support rod 1 on the bottom with pins 3 on the vehicle frame and secure with cotter pin 4.
Remove front bumper completely (depending on model) or loosen it, pull it out and tilt it downward.
9.2 Reinstalling the drive shaft after tilting the cab

Check the drive shaft for ease of movement and operation of joints and slider.
If the drive shaft is damaged, replace it with a new drive shaft.
Attach the drive shaft with assistance of markings that were made.
10 Electrical system - lighting

The maintenance of the electrical system is essentially limited to replacing defective fuses and bulbs
and maintaining the batteries.
NOTICE
Damage to electrical system!
Never short circuit defective fuses with wire or similar items!
Always replace defective fuses with fuses of the same amperage!
If there is a repeat problem with the same fuse, check the electrical system!
10.1 Battery maintenance

DANGER
Always disconnect the batteries from the power circuits when working on the electrical system of
the crane and during all welding work!
Keep batteries dry and clean.

Do not bring oil, grease, fuel or solvents into contact with the battery casting compound.
7.04 LIEBHERR 947

Remove dirty terminals, clean and grease them with an acid-free and acid-resistant grease.
Check the acid levels in batteries at least once a year. In summer and in hot climate zones, check
it at least twice a year.
On conventional batteries, check electrolyte level at regular intervals and add distilled water to the
specified “max mark”, if necessary.
When adding distilled water:
Measure the acid concentration only after 30 minutes. The acid temperature for measuring should
be + 20 °C if possible.
Proceed as follows when checking the battery charge:
Specific weight Charge condition

1.28/1.23* well charged
1.20/1.16* semi-charged, recharge
1.12/1.08* discharged, recharge imme-
diately
* in tropical countries
Reduced battery performance requires greater power requirements.
Ensure that batteries are well charged, particularly during the colder months.
10.2 Mixing battery acid

Ensure that work area is well ventilated.
DANGER
Risk of explosion!
When mixing battery acid, always pour distilled water into the container first, then the concentrated
sulphuric acid!
Observe this order, otherwise explosions and spattering can occur!
Stir the mixture with an acid-proof stick (glass or plastic).
Desired acid density kg/l 1.23 1.24 1.25 1.26 1.27 1.28
Volume ratio of concentrated sulphuric acid 1:3.8 1:3.6 1:3.4 1:3.2 1:3.0 1:2.8
(96%) to distilled water
When adding the battery acid, the acid level should be 15 mm above the top edge of the battery
plates and the temperature of the acid should be approximately 15 °C.
Add battery acid to battery.
Wait approximately 20 minutes before connecting the battery. By that time, it will be balanced out.
Connect the battery after approximately 20 minutes.
10.3 Removing and recharging the battery

WARNING
Danger of injuries!
Do not place tools on batteries and keep open flames away!
948 LIEBHERR 7.04

10.3.1 Removing the battery

– All electrical consumers are turned off.
NOTICE
Damage to alternator!
Do not disconnect batteries unless the engine has been turned off!
Carry out work in well ventilated areas and avoid spark formation.
Disconnect the negative terminal first (ground cable), then the positive terminal.
Remove the battery.
Avoid spark formation caused by electrostatic charge. To avoid this, touch the ground support
point in the driver's cab.
Do not tilt or shake the battery.
10.3.2 Recharging the battery
NOTICE
Damage to battery!
Recharge only with direct current, the strength of which does not exceed 1/10 of the battery
capacity!
Recharging example: A battery with 170 Ah should be charged with a maximum charging current of
17.0 A.
Frozen batteries must be thawed out before charging.
Remove all plugs before charging.
Provide ventilation during charging (risk of oxyhydrogen gas explosion!).
Connect the battery to a battery charger (positive to positive and negative to negative).
Turn on the battery charger after connecting the battery.
Stop charging immediately if:

– The acid temperature exceeds 55 °C (casing more than warm to the touch).
– The battery starts to give off gas.
– The acid concentration or the charging voltage has not changed for 2 hours.
Turn the battery charger off after charging, then remove the connector cables individually from
battery and battery charger.
10.3.3 Installing the battery

Reinstall the battery tightly in the vehicle.
Avoid spark formation caused by electrostatic charge. To avoid this, touch the ground support
point in the driver's cab.
Connect the positive terminal to the battery first, then the negative terminal (ground cable).
Check that the terminals are tightly seated (low contact resistance).
Grease the terminals and terminal posts with acid-free and acid-resistant grease (use corrosion
protection even for modern maintenance-free batteries).
7.04 LIEBHERR 949

027099-01 7.05 Maintenance guidelines - Crane superstructure
B199889
950 LIEBHERR 7.05

7.05 Maintenance guidelines - Crane superstructure 027099-01
1 Crane engine
Never step on fuel lines during maintenance or repair work in the engine area!
DANGER
Risk of fire!
Please ensure that the engine area is kept free of diesel fuel.
Extreme cleanliness is vital, particularly during filter changes and bleeding. Wipe up any spilled
fuel!
When replacing the filter, it is recommended to put down cleaning rags before removing the filter in
order to absorb fuel.
1.1 Engine oil

– The engine is turned off and the oil has collected in the oil pan.
The oil level must be between the min. and max. marks on the dipstick 1.
CAUTION
Risk of damaging the engine!
If the oil level has dropped below the minimum mark, add engine oil according to the lubrication chart
until the oil level is between the minimum and maximum marks.
Add engine oil and check again.

Refer to the separate operating instructions for “LIEBHERR Diesel engines”.
7.05 LIEBHERR 951

B199890
952 LIEBHERR 7.05

1.2 Coolant Engine cooling

The coolant level is monitored by the LICCON computer system. If the coolant level is too low the
icon 13 “Coolant level too low” appears on the LICCON monitor.
The coolant temperature for the crane engine can be read on the LICCON monitor in [°] on the
“Engine coolant temperature” icon 12.
DANGER
Risk of skin burns!
The engine must be cold when checking the coolant.
Turn the cap 2 on the filler neck of the water cooler expansion tank to the 1st notch.
Release excess pressure.
Remove the cap 2.
Add coolant as specified in the lubrication chart only on the filler neck of the water cooler expansion
tank.
Add coolant to overflow level if necessary.
1.3 Air filter

The air filters are monitored by the LICCON computer system. If the vacuum increases in the intake
line due to dirty filter units, the “Air filter contaminated” 14 icon is displayed on the LICCON monitor.
If the “Air filter contaminated” 14 icon appears:
Clean or replace filter unit.
1.4 Diesel particle filter*

DANGER
Danger of igniting the diesel particle filter*!
The diesel particle filter* may only be regenerated under the supervision of operating personnel!
Carry out the operation and maintenance of the diesel particle filter* according to the separate
operating instructions of the diesel particle filter* manufacturer.
7.05 LIEBHERR 953

B198428
954 LIEBHERR 7.05

2 Pump distributor gear


Ensure that the crane is horizontal.
CAUTION
Risk of transmission damage!
If the oil level has dropped below the minimum mark, add oil according to the lubrication chart until the
oil level is between the minimum and maximum mark.

– The transmission has warmed up.
Install the oil drain plug 3 with new seal and tighten.
Add oil as specified in the lubrication chart on the oil filler plug 2 until the oil level is between the
min. and max. marks on the dipstick 1.
Install the oil filler plug 2 with new seal.
7.05 LIEBHERR 955

B199891
956 LIEBHERR 7.05

3 Hydraulic system
When adding oil, observe utmost cleanliness.
3.1 Hydraulic oil tank

– The luffing cylinder and the telescoping cylinder are fully retracted.
The oil level must be in the center of the oil level sight gauge 1.
Check the oil level on the oil level sight gauge 1 of hydraulic oil tank.
Troubleshooting
No oil is visible in the oil level sight gauge 1?
Add oil as specified in the lubrication chart using a fine-mesh strainer until oil level is in center of
the oil level sight gauge 1.
3.1.2 Checking the vent / breather filter

Open the cover with turn lock.
Check the filters 2 for impurities (visual inspection).
In the event of heavy soiling:
Replace the filters 2.
Close the cover with the turn lock again.
Start engine.
Perform all crane movements slowly.
7.05 LIEBHERR 957

B199892
958 LIEBHERR 7.05

3.2 Pressure filter in the crane hydraulic

The pressure filter 4 and pressure filter 5 are equipped with a maintenance indicator. If the red bar
indicator is visible when the oil is at operating temperature, then the filter cartridge must be replaced.
Turn off the engine.
Release the filter cartridge and collect any escaping oil in a suitable container.
Unscrew, remove and dispose of filter cartridge.
Clean the sealing surface on the filter bracket.
Lubricate the rubber seal ring on the new oil filter cartridge with oil.
Screw on and tighten new filter cartridge.
Start engine and check for leaks.
Perform all crane movements slowly.
Result:
3.3 In-line filter in crane hydraulics

The in-line filter 6 is equipped with a maintenance indicator.
If the indicator moves into the red zone when the fluid is warmed up ready for operation the filter must
be changed.
Turn the crane engine off.
Properly dismantle the filter.
Properly assemble the new filter.
Start the crane's engine and check the filter for leaks.
Slowly go through all crane movements, this will deaerate the hydraulic system.
Result:
3.4 Diaphragm reservoir

Various diaphragm reservoirs are installed in the hydraulic system. The pretension pressures are
specified in the hydraulic circuit diagram as well as on the individual diaphragm reservoirs. The
pretension pressure must be measured separately in each diaphragm reservoir.
CAUTION
Risk of damaging the hydraulic system!
If the outside temperature fluctuates considerably, e.g. after transport to extremely hot or cold
countries or in countries with considerable differences between the summer and winter temperatures,
the gas accumulator pressures may change.
Check the gas accumulator pressures and correct if necessary.

– The crane engine is turned off.
This relieves the diaphragm reservoir at the fluid side.
7.05 LIEBHERR 959

DANGER
Risk of explosion!
The pressure in the nitrogen cylinder must be less than the maximum permissible operating pressure
of the accumulator or the pressure gauge. Otherwise install a pressure reducer between the cylinder
and the filling device.
Do not use air or oxygen to fill the diaphragm reservoir.
The pretension pressure in the hydraulic reservoirs may only be checked by an expert with
appropriate training and equipment. In addition, the national regulations for pressurized container
inspections must also be observed.
Check the pretension pressure with a testing and filling device and correct it, if necessary.
3.5 Hydraulic hose lines

The hydraulic hose lines must be checked according to ISO 9927-1 by an experienced technician or
expert mechanic, as required, depending on the duration of use and the operating conditions, but at
least once a year.
Experienced technicians are persons who have adequate knowledge of cranes because of their
professional background and experience and are adequately familiar with the relevant settings to
detect deviations from the correct situation (i.e. specially trained personnel).
Expert mechanics are mechanics who have experience in the design, construction or maintenance
of cranes and have adequate knowledge of the relevant settings and standards and the necessary
equipment to perform an inspection, and are in a position to assess the safety standards of the crane
and decide which action needs to be taken to ensure that the crane can continue to be operated
safely.
Note
Note
The applicable national regulations must also be complied with!
3.5.1 Checking the hydraulic hoses within area of responsibility of the German
employer's liability insurance associations
At least once a year, an expert must check whether the hydraulic hoses are in a safe condition. The
crane must be inspected by an authorized inspector every four years from the day it was first
licensed. After the 12th year of operation, the crane must be inspected annually by an authorized
inspector.
The expert or authorized inspector must document the fact that the hydraulic hoses can continue to
be used in the crane!
An expert is someone whose technical training and experience means that they have adequate
knowledge in the field of hydraulic hoses and hose systems and are adequately familiar with the
relevant national work safety regulations, accident prevention regulations, directives and generally
accepted technical regulations (e.g. DIN standards, VDE regulations, technical regulations of other
EU member states or other countries that have signed the European Economic Community
agreement) that they are in a position to assess whether hydraulic hoses and hose systems are are
safe to work with.
An authorized inspector is someone employed by supervisory authorities. In Hamburg this is the
Amt für Arbeitsschutz (work safety office) and in Hessen it is the technical supervisory offices or an
authorized inspector employed by the professional associations.
960 LIEBHERR 7.05

3.5.2 Examples of possible defects in hose lines
DANGER
If problems are discovered during inspections, then they must be remedied immediately or suitable
measures are to be taken. Failure to do this can result in serious injury to persons, death or damage
to property.
Remedy problems or take suitable measures!
– Damage to the outer layer as far as the intermediate layer (e.g. chafing, cuts and cracks)
– Outer layer brittleness (crack formation of the hose material)
– Deformation that differs from the natural shape of the hose or hose line, in depressurized as well
as in pressurized condition or in bends, for example layer separation, bubbling, crushing or kinking
– Leaks
– Failure to follow installation instructions
– Damage or deformation of hose fittings that inhibit the function and strength of the fitting or the
hose / fitting connection
– Hose slipping out of fitting
– Fitting corrosion that inhibits function and strength
– Storage time or usage period exceeded
3.5.3 Maintenance of hose lines

– We recommend to check all hoses, hose lines and screw fittings daily, but at least every two
weeks for leaks and externally recognizable signs of damage.
– Damaged parts must be replaced immediately! Oil spray can lead to injuries and fires!
– Hydraulic lines and hoses may not be repaired!
– Hoses that have already been used in a hose system may not be reinstalled in hose systems.
– Always use original Liebherr spare parts when replacing hoses and hose systems.
– Always ensure that the hoses are routed free of torsion. If high pressure hoses are being used,
attach screws of half clamps or full flange at both ends of hose and then tighten.
– When using high pressure hoses with a bent fitting, tighten the end with the bent fitting first when
tightening the flanges, then the end with the straight fitting.
– Any mounting clamps in the hose center may be attached and tightened only thereafter.
– Route the hoses in such a way that chafing with other hoses or other structures is prevented.
Maintain a minimum clearance of approximately ½ the outer diameter of the hose to other parts.
The clearance may never be less than 10 to 15 mm.
3.5.4 Replacing the hose lines
DANGER
Failure to replace hose systems at appropriate intervals can cause serious injury to persons, death or
damage to property.
Replace hose lines at appropriate intervals!
This must be documented in the crane's log book by the expert or the authorized inspector.
The service life of a hose system may not exceed six years, including a storage period of a maximum
of two years (observe the manufacturing date on the hoses). The duration of use can also be defined
by the expert or authorized inspector in accordance with existing test and empirical data in the
individual application areas, taking the usage conditions into consideration.
7.05 LIEBHERR 961

B103451
962 LIEBHERR 7.05

4 Central lubrication system

The crane superstructure is equipped with a central lubrication system. All lubricating points (refer to
the guide on the left), the roller slewing ring, the bearing of the pivot section, the bearings of the luffing
cylinder and the hoisting winches are automatically supplied with the correct grease quantity.
If the crane has not been moved for more than 3 months, then it must be lubricated every 3 months
with an external grease pump until grease emerges from all grease points. Then the relevant crane
movement must be repeated several times and the lubrication procedure must be carried out again.
– Pump operation period: 6 cycles
– Break period: 3 hours
Note
Cleaning is permitted in washing bays or with steam cleaners!
4.1 Components of the system

– Grease container 1
– Grease fitting 2: Filling the central lubrication pump
– Grease fitting 3: Filling the lube lines
– Pump outlet 4
– Pressure relief valve 5
– Pump element 6
– Push button 7
– Control 8
– LED 9 (green): Function display
– Latched switch 10: Pause time (h)
– Latched switch 11: Cycles
– LED 12 (red): Fault display
4.2 Setting the lubrication and break periods

During the lubrication procedure, the LED 9 on the engine protection housing lights up statically. The
lubrication and interval time is set at the factory. The times can possibly be changed by using the
latched switch 10 and latched switch 11.
Turn on the engine ignition.
Result:
– When turning the ignition on, the LED 9 lights up for approximately 2 seconds and displays the
operational readiness of the control 8.
4.3 Function check

Start the engine.
Trigger 2 or 3 grease pulses via the push button 7.
Result:
– Grease emerges on the grease points.
– If the system is blocked but the electric pump is properly functioning, the grease emerges through
the pressure relief valve 5.
7.05 LIEBHERR 963

B103451
964 LIEBHERR 7.05

4.4 Cycle control

The central lubrication system is progressively monitored. This means that a proximity switch converts
the piston strokes of the central lubrication system distributor into electric control signals and relays
them to the control unit. If the control signals are not present or incomplete, the indicator
light 340 displays a malfunction or a problem by blinking.
4.4.1 Blinker code - cycle control

During operation
– Ignition on, ready for operation:
The indicator light 340 lights up for 1.5 s and turns off.
– Active lubrication:
The indicator light 340 lights up statically.
In case of a problem
– Error of monitoring period of cycle input, lubrication time larger monitoring period cycle input
The indicator light 340 lights up for 1 s and is off for 1 s etc.
– Error CPU, Error memory
The indicator light 340 lights up for 0.5 s and is off for 0.5 s etc.
4.5 Access into the automatic lubrication (intermediate lubrication)

This allows intermediate lubrication processes to be carried out after crane washing, or the grease
lines are re-filled with grease after a repair.
With the ignition turned on, press the red button 7 on the engine protection housing of the pump.
4.6 Filling the grease container

CAUTION
Risk of damage due to insufficient lubrication!
There must be sufficient grease in the grease container 1 at all times.
Observe utmost cleanliness when filling the grease container 1!
Fill the grease container 1 with a grease pump via the grease fitting 2 on the central lubrication
pump.
7.05 LIEBHERR 965

B103451
966 LIEBHERR 7.05

4.7 Bleeding the central lubrication system

If the grease container 1 has been emptied, then it may be necessary to bleed the central lubrication
system.
Fill the grease container 1.
Unscrew the main line from the pump outlet 4.
Trigger additional lubricating pulses until there are no more air bubbles in the emerging grease at
the pump outlet 4.
Reconnect the main line.
Trigger an additional lubricating process.
4.8 Filling the lubrication lines

CAUTION
Risk of damage due to insufficient lubrication!
The lubrication lines must be refilled after any repair on components, which are lubricated with
grease. If this is not observed, the component may run dry.
Sufficient grease must be available in the grease lines after every repair on greased components.
Observe utmost cleanliness when filling the grease lines!
Add grease with an external grease pump via the grease fitting 3.
or
With the ignition turned on, press the red button 7 on the engine protection housing of the pump.
7.05 LIEBHERR 967

B103451
968 LIEBHERR 7.05

4.9 Central lubricating system, troubleshooting
Problem Cause Remedy

Pump is not working Integrated electronic control de- Replace lower part of motor
fective, electrical line interrupt- protection housing, replace
ed, pump defective electrical line, replace pump
Pump operates, but does not Air cushion in delivery piston Bleed pump, fill reservoir, re-
deliver has dropped below minimum fill place pump element
level, pump element defective
No grease collar on all lube Pump not operating, interval See “Pump not operating” , re-
points time too high or cycle time too duce interval time or increase
short, system blocked number of cycles, refer to
“Grease emerges on pressure
relief valve”
No grease collar on several Supply lines to secondary dis- Replace lines, tighten or re-
lube points tributors broken or leaking, place screw connections
screw connections leaking
No grease collar on one lube Associated lube line broken or Replace line, tighten or replace
point leaking, screw connection leak- screw fitting
ing
Pump speed reduced Higher system pressure, lower Check system / bearing points,
ambient temperature no damage: Try 1 or 2 interme-
diate lubrication operations
Grease escapes at the pressure System pressure too high, pro- Check system, replace distribu-
relief valve gressive distributor blocked, tor, repair blocked / seized
system blocked, defective valve bearing point, replace pressure
spring relief valve
Red LED lights up in 0.5 se- Error CPU / memory Consult Liebherr service
cond interval
Red LED and control light blink Error in the monitoring period Proximity switch is defective,
in 1 second interval from cycle start possibly consult Liebherr or
BekaMax customer service
7.05 LIEBHERR 969

B105098
970 LIEBHERR 7.05

5 Slewing ring connection
5.1 Lubricate the rotary connection

Perform lubrication with extreme care before and after long operating intervals, particularly before and
after any winter break, in order to provide the best possible corrosion protection.
If the crane has not been moved for more than 3 months, then it must be lubricated every 3 months
with an external grease pump until grease emerges from all grease points, see also section of
“Central lubrication system”. Then the relevant crane movement must be repeated several times and
the lubrication procedure must be carried out again.
Lubricate the rotary connection.
5.2 Lubricating the gear ring and the slewing gear pinion
Before and after extended breaks in service, grease the gear ring 1 and the slewing gear pinion 2 to
ensure the best possible protection from corrosion.
Grease the gear ring 1 and the slewing gear pinion 2 externally.
5.3 Tilt play of roller ring connection

The wear of the roller ring connection is determined by measuring the “tilt play” with the ring installed.
Note
The determination of the “tilt play” must be carried out according to the test instructions of
Liebherr-Werk Ehingen GmbH.
Contact the Service Dept. at Liebherr-Werk Ehingen GmbH for test instructions.
DANGER
Danger of accident if tilt play of roller ring connection is too large!
If the permissible tilt play of 2.0 mm is exceeded, then safe crane operation is no longer possible.
Replace the roller ring connection if the tilt play is larger than 2.0 mm!
7.05 LIEBHERR 971

B196564
972 LIEBHERR 7.05

6 Hoist gears
6.1 Winch 1, winch 2*
6.1.1 Overflow container

When the oil heats up in the hydraulic motor of winch 2*, the oil can enter the overflow container via a
check valve, but cannot flow back into the hydraulic system after cooling. For this reason the oil that
has collected in the overflow container must be disposed of at regular intervals.
6.2 Hoist gear

– The hoist gear is inactive.

CAUTION
If the oil level has dropped below the minimum mark, add oil according to the lubrication chart until the
oil level is between the minimum and maximum mark.

Unscrew the vent screw 2.
Unscrew the oil drain plug 3 with seal ring and drain oil into a suitable container.
Unscrew oil dipstick 1 to open the oil filler opening.
Add oil at oil filler port according to the lubrication chart.
Screw in and tighten the vent screw 2.
Check the oil level as described above.
7.05 LIEBHERR 973

B196564
974 LIEBHERR 7.05

6.3 Winch brake

– The hoist gear is inactive.

Remove the screw 4.

CAUTION
If the oil level has dropped, add the oil as specified in the lubrication chart until it overflows on the
filler port.
Clean the sealing surfaces on the housing and on the plug.

Reinstall the screw 4 and tighten.

Remove the oil filler plug 5 and clean the sealing surface.
Unscrew the oil drain plug 6 with seal ring and drain oil into a suitable container.
Clean the oil drain plug 6 and sealing surface on the housing.
Add oil according to the lubrication chart on the filler port until the oil starts to overflow at the
opening 4.
Clean the oil filler plug 5 and reinstall it with a new seal ring and tighten.
7.05 LIEBHERR 975

B196558
976 LIEBHERR 7.05

7 Slewing gear

The oil level must be between the two notches on the dipstick 1.
CAUTION
If the oil level has dropped below the lower notch, add oil according to the lubrication chart until the oil
level is between the two notches.

– The gear has warmed up.
Open the oil filler port by unscrewing the dipstick 1.
Remove the oil drain plug 2 with the seal ring and drain the oil.
Clean the oil drain plug 2 and sealing surface on the housing.
Add oil as specified in the lubrication chart on the oil filler port until the oil level is between the two
notches on the dipstick 1.
Close the oil filler port by screwing in the dipstick 1.
7.05 LIEBHERR 977

B199893
978 LIEBHERR 7.05

8 Air dryer of the compressed air system of the crane

superstructure
The air dryer 1 of the compressed air system of the crane's superstructure is maintenance-free.
8.1 Replacing the granular cartridge

CAUTION
Danger!
The granular cartridge is under spring tension.
Caution when replacing the granular cartridge.
Replace the granular cartridge once a year.
9 Electrical system - Lighting

Maintain electrical system and lighting in crane superstructure according to the maintenance data in
chapter 7.04.
CAUTION
Loss of the settings if the power supply has been interrupted!
The winch and the slewing gear must be re-calibrated after the power supply has been interrupted
from the central unit or the power unit in the crane superstructure (for example, clamping off the
battery).
7.05 LIEBHERR 979

B195757
980 LIEBHERR 7.05

10 Telescopic boom
10.1 Lubricating the telescopic boom

– The crane is properly supported and level.
– The counterweight has been attached to the turntable according to the load chart.
– The LICCON overload protection has been set according to the data in the load chart.
The inner gliding surfaces of the telescoping sections (plastic glide bearing plates) are lubricated via
the grease fittings in the bearing shoes.
These grease fittings can be accessed from the outside via inspection ports on both sides of the pivot
section as well as the telescope sections.
Telescope out telescopic section 5 to 92 % and pin.
Unpin the telescoping cylinder, retract into telescopic section 4 and pin telescoping cylinder to
telescopic section 4.
Telescope out telescopic section 4 until the grease fittings of telescopic section 5 become visible
on the inspection ports at 92 %.
Lubricate telescopic section 5 on the inspection ports
Retract telescopic section 4 to 0 % and unpin the telescoping cylinder.
Extend telescoping cylinder and bolt to telescopic part 5.
Telescope in telescopic section 5 to 46 % and pin.
Unpin telescoping cylinder and retract into telescopic section 4.
Pin telescoping cylinder with telescopic section 4.
Telescope out telescopic section 4 until the grease fittings of telescopic section 5 become visible
on the inspection ports at 46 %.
Lubricate telescopic section 5 on the inspection ports
Telescope telescopic section 4 and 5 in to 0 %.
Lubricate telescopic parts 4, 3 and 2 in the same way as telescopic part 5.
Bolt telescoping cylinder into telescopic part 1.
Telescope telescopic section 1 out to 46 %, pin and grease.
Telescope telescopic section 1 out to 92 %, pin and grease.
Use the special grease specified in the lubrication chart to grease the inner and outer glide surfaces of
the telescopic sections.
After spraying on the special grease, allow it to harden for 4 to 8 hours.
Spray special grease onto the outer glide surfaces of the telescopic sections.
7.05 LIEBHERR 981

026699-02 7.06 Fill quantities, lubrication chart
B109767
982 LIEBHERR 7.06

7.06 Fill quantities, lubrication chart 026699-02
1 Fill quantities
1.1 Fill quantities for crane chassis

The specified filling quantities (change quantities) are orientation values. The marks on the dipsticks,
inspection ports and sight gauges are decisive for filling.
NOTICE
Danger of property damage!
Do not mix synthetic oils with mineral oils!
Position Component Fill quantity

1 Diesel engine 33.0 l
2 Cooling system 88.0 l
3 Fuel tank 475.0 l
4 Automatic transmission 21.0 l
6 Transfer gear box 5.5 l , oil cooler and lines 3.2 l
Total fill quantity: 8.7 l
7 1. Axle, axle drive 14.5 l
1. Axle, per wheel side 1.4 l
11 Hydraulic oil tank, crane chassis 1 (oil change volume) 185.0 l
Contents lines 165.0 l
1 Before checking the oil level, retract all hydraulic cylinders and lower the vehicle all the way via the leveling regulation. The oil
level must be in the center of the sight gauge.
7.06 LIEBHERR 983

B109768
984 LIEBHERR 7.06

1.2 Fill quantities for crane superstructure and boom

The specified filling quantities (change quantities) are orientation values. The marks on the dipsticks,
inspection ports and sight gauges are decisive for filling.
NOTICE
Danger of property damage!
Do not mix synthetic oils with mineral oils!
Position Component Fill quantity

1 Diesel engine 25.0 l
2 Cooling system 47.0 l
3 Fuel tank 265.0 l
4 Winch 1 5.0 l
Winch brake, winch 1 0.75 l
5 Winch 2* 5.0 l
Winch brake, winch 2* 0.75 l
6 Slewing gear (right / left), each slewing gear 3.2 l
7 Pump distributor gear 2.0 l
8 Hydraulic oil tank1 830.0 l
9 Central lubrication system 2.5 kg
1 When the oil level is checked, all hydraulic cylinders must be retracted. The oil level must be in the center of the sight gauge.
7.06 LIEBHERR 985

B109769
986 LIEBHERR 7.06

2 Lubrication schedule
2.1 Lubrication schedule - Crane chassis
Note
The lube points are marked with this icon.
7.06 LIEBHERR 987

B109770
988 LIEBHERR 7.06

2.2 Lubrication schedule - Crane superstructure and boom
Note
7.06 LIEBHERR 989

B108145
990 LIEBHERR 7.06

2.3 Lubrication schedule - Equipment
2.3.1 Lubrication schedule - Hook block / load hook
Note
7.06 LIEBHERR 991

023098-24 7.07 Service fluids and lubricants
B195219
992 LIEBHERR 7.07

7.07 Service fluids and lubricants 023098-24
1 Service items and lubricants required for LIEBHERR

cranes
1.1 Service items and lubricants

Note
To improve the cold start ability of the diesel engine at an ambient temperature below -10 °C, we
recommend the use of the following engine oil:
Viscosity grade SAE 5W-30 according to specification ACEA E4.
LWE Id. No.: 10425711!
Usage Ambient temperature for driving and crane operation

-25 °C to +50 °C -40 °C to +30 °C
1 Diesel engine LWE Id. No.: 8610240 LWE Id. No.: 8610240
SAE 10W-40 SAE 10W-40
API CF API CF
ACEA E4-96 ACEA E4-96
Below -20 °C with pre-heating Below -20 °C with pre-heating
2 Drive axle LWE Id. No.: 861901008 LWE Id. No.: 10425142
With differential locks, SAE 90 SAE 75W-90
Planetary gear and API GL 5 API GL 5
Installed distributor gear ZF TE-ML 05 ZF TE-ML 05
3 Axle drive ZF DK-7 LWE Id. No.: 861901008 LWE Id. No.: 10425142
SAE 90 SAE 75W-90
API GL 5 API GL 5
ZF TE-ML 05 ZF TE-ML 05
4 Vehicle distributor gear LWE Id. No.: 861901008 LWE Id. No.: 10425142
KESSLER SAE 90 SAE 75W-90
VG 1800 / 2400 /2550 / 2600 / 3750 API GL 5 API GL 5
W 3750 ZF TE-ML 19 ZF TE-ML 19
ZF Passau, STEYR PUCH
VG 1200 / 1600 / 2000 / 3800
7.07 LIEBHERR 993

1.2 Service items and lubricants (continuation)

-25 °C to +50 °C -40 °C to +30 °C
5 Drop box LWE Id. No.: 861901008 LWE Id. No.: 10425142
ZF Passau, STEYR PUCH SAE 90 SAE 75W-90
API GL 5 API GL 5
6.1 Pump distributor gear LWE Id. No.: 861901008 LWE Id. No.: 10425142
Filled with mineral gear oil SAE 90 SAE 75W-90
API GL 5 API GL 5
Filled with synthetic gear oil ISO VG 220, DIN 51 519 ISO VG 150, DIN 51 519
CLP PG 220, DIN 51 502 CLP PG 150, DIN 51 502
Do not mix with mineral oils! Do not mix with mineral oils!
LTC 1055-3.1 SAE 75W-90 SAE 75W-90
API GL 5 API GL 5
7.1 Load powershift gear box LWE Id. No.: 8610240 LWE Id. No.: 861900608
ZF torque converter SAE 10W-40 ATF Dexron II D
WG 120, WG 150 API CF ALLISON C4
WG 180, WG 181, WG 200, WG 201 ACEA E2-96, E4-96
Below -20 °C run warm as Below -20 °C run warm as
described in the operating described in the operating
instructions instructions
994 LIEBHERR 7.07


-25 °C to +50 °C -40 °C to +30 °C
7.2 Load powershift gear box LWE Id. No.: 861900608 LWE Id. No.: 861900608
ZF torque converter WG 251* ATF Dexron II D ATF Dexron II D
ZF ERGOPOWER ZF TE-ML 03 ZF TE-ML 03
WG 210, WG 260, WG 310 Below -20 °C run warm as Below -20 °C run warm as
* also for ambient temperatures above
-10 °C
8 Load powershift gear box LWE Id. No.: 8610240 LWE Id. No.: 861900608
CLARK SAE 10W-40 ATF Dexron II D
API CF ALLISON C4
ACEA E2-96, E4-96
9 Drop box LWE Id. No.: 8610240 LWE Id. No.: 861900608
ALLISON SAE 10W-40 ATF Dexron II D
API CF ALLISON C4
ACEA E2-96, E4-96
7.07 LIEBHERR 995


-25 °C to +50 °C -40 °C to +30 °C
10.1 Automatic transmission ATF Dexron III LWE Id. No.: 861903708
ALLISON ALLISON C4 CASTROL Transynd
CLBT 740, CLBT 750, CLBT 754, Below -20 °C run warm as Below -20 °C run warm as
CLBT 755, HT 755, HD 4560 described in the operating described in the operating
10.2 Automatic transmission LWE Id. No.: 861900608 LWE Id. No.: 861900608
ZF ATF Dexron II D ATF Dexron II D
11 Automatic gear box LWE Id. No.: 10218305 LWE Id. No.: 10218305
ZF AS-Tronic ZF-Ecofluid M ZF-Ecofluid M
ZF TC-Tronic ZF TE-ML 02 ZF TE-ML 02
ZF TC-Tronic HD below -20 °C pre-heat
gearbox as described in the
operating instructions
12.1 Torque converter transmission LWE Id. No.: 10218305 LWE Id. No.: 10218305
ZF TC HD ZF-Ecofluid M ZF-Ecofluid M
below -20 °C pre-heat
gearbox as described in the
operating instructions
12.2 Torque converter transmission LWE Id. No.: 861900608 LWE Id. No.: 861900608
ZF TC 2 ATF Dexron II D ATF Dexron II D
996 LIEBHERR 7.07


-25 °C to +50 °C -40 °C to +30 °C
13 Gear box LWE Id. No.: 861004208 LWE Id. No.: 10425142
ZF ECO-Split Engine oil or gear oil SAE 75W-90
14 Rope winch LWE Id. No.: 861901208 LWE Id. No.: 861901208
ISO VG 220, DIN 51 519 ISO VG 220, DIN 51 519
15 Slewing gear LWE Id. No.: 861901208 LWE Id. No.: 861901208
ISO VG 220, DIN 51 519 ISO VG 220, DIN 51 519
16 Winch LWE Id. No.: 861901208 LWE Id. No.: 861901208
Telescopic boom guying ISO VG 220, DIN 51 519 ISO VG 220, DIN 51 519
7.07 LIEBHERR 997


-25 °C to +50 °C -40 °C to +30 °C
17.1 Crane hydraulics LWE Id. No.: 861903508 LWE Id. No.: 10467552
Crane chassis and crane superstructure Liebherr Hydraulic 37 Liebherr Hydraulic FFE 30
or
LWE Id. No.: 10293807
LTC 1055–3.1 Liebherr Hydraulic FFE 30 Liebherr Hydraulic FFE 30
or or
LWE-Identnr.: 10293807 LWE-Identnr.: 10293807
Liebherr Hydraulic Plus Arctic Liebherr Hydraulic Plus Arctic
LTM 11200–9.1 Liebherr Hydraulic FFE 30 Liebherr Hydraulic FFE 30
Crane chassis and crane superstructure or or
LTR 11200 LWE-Identnr.: 10293807 LWE-Identnr.: 10293807
Crane superstructure Liebherr Hydraulic Plus Arctic Liebherr Hydraulic Plus Arctic
18 Brake system LWE Id. No.: 861000108 LWE Id. No.: 861000108
if hydraulically actuated DOT 4 DOT 4
SAE J 1703e SAE J 1703e
19 Clutch actuator LWE Id. No.: 861000108 LWE Id. No.: 861000108
DOT 4 DOT 4
SAE J 1703e SAE J 1703e
998 LIEBHERR 7.07


-25 °C to +50 °C -40 °C to +30 °C
20 King pin bearing Special regulations: Special regulations:
LIEBHERR LIEBHERR
Gear shaft LWE Id. No.: 861301308 LWE Id. No.: 861301308
if not maintenance-free Special grease 9610 PLUS Special grease 9610 PLUS
21 Slide and roller bearing Special regulations: Special regulations:
LIEBHERR LIEBHERR
roller bearing joint LWE Id. No.: 861301308 LWE Id. No.: 861301308
Special grease 9610 PLUS Special grease 9610 PLUS
22 Central lubrication system Special regulations: Special regulations:
LIEBHERR LIEBHERR
LWE Id. No.: 861301308 LWE Id. No.: 861301308
23 Boom lock Special regulations: Special regulations:
LIEBHERR LIEBHERR
LWE Id. No.: 861301308 LWE Id. No.: 861301308
24 Rotary connection Special regulations: Special regulations:
LIEBHERR LIEBHERR
Roller bearing LWE Id. No.: 861301308 LWE Id. No.: 861301308
25 Support pad with equalization Special regulations: Special regulations:
LIEBHERR LIEBHERR
LWE Id. No.: 861303608 LWE Id. No.: 861303608
Special grease 9613 Plus Special grease 9613 Plus
7.07 LIEBHERR 999


-25 °C to +50 °C -40 °C to +30 °C
26 Plastic slide bearing Special regulations: Special regulations:
LIEBHERR LIEBHERR
Sliding beam LWE Id. No.: 861303608 LWE Id. No.: 861303608
27 Plastic slide bearing Special regulations: Special regulations:
LIEBHERR LIEBHERR
Telescopic boom LWE Id. No.: 861303608 LWE Id. No.: 861303608
28 Outer slide bearing Special regulations: Special regulations:
LIEBHERR LIEBHERR
Guide rail on Special grease 1336 with Special grease 1336 with
Telescoping cylinder Solvent LM (spray grease) Solvent LM (spray grease)
29 Inner slide bearing Special regulations: Special regulations:
LIEBHERR LIEBHERR
(only during assembly) Special grease 1336 with Special grease 1336 with
Solvent LM (spray grease) Solvent LM (spray grease)
30 Gear ring rotary connection LWE Id. No.: 861301508 LWE Id. No.: 861301508
Slewing gear pinion Adhesive grease Adhesive grease
OGPF 2 S-30, DIN 51 502 OGPF 2 S-30, DIN 51 502
(water-resistant) (water-resistant)
1000 LIEBHERR 7.07


-25 °C to +50 °C -40 °C to +30 °C
31 Running rope LWE Id. No.: 861301508 LWE Id. No.: 861301508
Adhesive grease Adhesive grease
OGPF 2 S-30, DIN 51 502 OGPF 2 S-30, DIN 51 502
(water-resistant) (water-resistant)
32 Radiator fluid Special regulations: Special regulations:
LIEBHERR LIEBHERR
Diesel engine and heating system LWE Id. No.: 861600508 LWE Id. No.: 861600508
50 % antifreeze fluid with 50 % antifreeze fluid with
corrosion inhibitor corrosion inhibitor
50 % water 50 % water
33.1 Drive transmission crawler crane see nameplate see nameplate
33.2 Drive transmission crawler crane LWE Id. No.: 861901008 LWE Id. No.: 10425142
LTR 1100 SAE 90 SAE 75W-90
API GL 5 API GL 5
34 Towing winch see nameplate see nameplate
35 Towing winch rope Special regulations: Special regulations:
LWE Id. No.: 861008608 LWE Id. No.: 861008608
Motorex TW-Fluid Motorex TW-Fluid
7.07 LIEBHERR 1001

028369-00 7.15 Procedure in case of problems
B197077
1002 LIEBHERR 7.15

7.15 Procedure in case of problems 028369-00
1 Procedure to follow in case of a problem

This chapter answers the following questions:
– What to do in case of a problem?
– Which data is important for communication with Liebherr Service?
– Which displays and component groups are relevant for error diagnostics?
– Which measures are to be taken in clear problem cases?
– How to proceed in case of error messages of the LICCON computer system?
– How can an error diagnostics be carried out?
– Which measures are to be taken for defective components?
WARNING
Incorrect operation!
Incorrect operation of the crane can result in death or serious injuries!
The crane may only be operated by authorized and trained expert personnel!
WARNING
Measures without the help of Liebherr Service!
Measures in case of a problem, which are carried out without consulting Liebherr Service can cause
damage to the crane. Personnel can be severely injured or killed!
If problems remain or in case of error messages, consult Liebherr Service to determine the cause
of the problem and further procedure.
Note
Error diagnostics without the help of Liebherr Service!
For information regarding error diagnostics and error remedy, see “Diagnostics manual”.
Note
The monitor illustrations in this section are only examples. The error codes shown in the monitor
illustrations and the corresponding error descriptions might not exactly match the crane.
1.1 Procedure to follow in case of a problem

Observe and adhere to the notes and instructions in this chapter.
Before contacting Liebherr Service: Determine relevant data about the problem.
Carry out the error diagnostics with the aid of Liebherr Service or the “Diagnostics manual”.
Follow the instructions given by Liebherr Service.
After error diagnostics: Replace defective components, which are supplied as spare parts.
7.15 LIEBHERR 1003

B110960
1004 LIEBHERR 7.15

1.2 Overview of displays and component groups for error diagnostics

Note
Displays and components in the driver's cab are only relevant for cranes with Liebherr crane
chassis!
Various displays and component groups allow the crane driver:

– To localize error messages
– To communicate quicker and more precise with Liebherr Service
– With the aid of the “Diagnostics manual”: To diagnose and remedy errors
Note
For information regarding error diagnostics and error remedy, see “Diagnostics manual”.
324 LICCON Monitor 0

I LED supply voltage
60 EMERGENCY OFF • Note:
switch on driver's cab Only for cranes with driver's cab.
650 Operating and control unit • Note:
(BKE) Only for cranes with operating and control unit (BKE).
651 EMERGENCY OFF • Note:
switch in the crane On cranes with operating and control unit (BKE), the
operator's cab EMERGENCY OFF switch 651 is installed on the BKE.
On cranes without operating and control unit (BKE), the
EMERGENCY OFF switch 651 may be installed on another
location in the crane operator's cab.
350 EMERGENCY OFF
switch on the crane
operator's cab
4 Bluetooth™ Terminal • Note:
(BTT) Only for cranes with Bluetooth™ Terminal (BTT).
550 Indicator light sending • Note:
signal BTT Only for cranes with Bluetooth™ Terminal (BTT).
552 Indicator light charge • Note:
condition BTT Only for cranes with Bluetooth™ Terminal (BTT).
Note
On certain crane models, the Bluetooth™ Terminal (BTT) 4 is installed in the crane operator's cab.
10 Fuses in driver's cab • Note:

Only for cranes with driver's cab.
17 Display unit • Note:
20 Fuses in crane operator's
cab
460 Touch display • Note:
Only for cranes with touch display.
7.15 LIEBHERR 1005

B110960
1006 LIEBHERR 7.15

1.3 Which data is required by Liebherr Service?

If the assistance of Liebherr Service is required, always provide the following information:
– Crane type
– Crane number
– Complete error code and any error message displayed on the LICCON monitor 0 324
– Complete error code and any error message from the BTT 4
– Application conditions of crane
– Action during which the error occurs
– Possibly frequency of error
2 Measures in clear problem cases

Note
Measures in clear problem cases from the driver's cab are only relevant for cranes with Liebherr
crane chassis!
Measures, which are taken in clear problem cases, are described in this section.
Note
If a problem occurs, which is not described in this chapter:
Contact Liebherr Service to determine the cause of the problem and further procedure.
Clear problem cases are:

– The sliding beam does not extend.
– Engine does not start.
– Hydraulic, electric or engine failed.
– An alarm function occurs.
– LICCON computer system shows an error message.
2.1 The engine does not start from the driver's cab?
Note
Make sure that the EMERGENCY OFF switch 651 in the crane operator's cab, the EMERGENCY
OFF switch 60 on the crane chassis and the EMERGENCY OFF switch 350 on the crane
operator's cab are not actuated.
Turn the ignition off.
Start the engine again.
If the engine still cannot be started:
Check the indicator lights on the display unit 17.
Note
For problem remedy, see Crane operating instructions, chapter 3.04.

7.15 LIEBHERR 1007

B110960
1008 LIEBHERR 7.15

2.2 The engine does not start from the crane operator's cab?
Make sure that the EMERGENCY OFF switch 651 in the crane operator's cab, the EMERGENCY
OFF switch 60 on the crane chassis and the EMERGENCY OFF switch 350 on the crane
operator's cab are not actuated.
Make sure that the crane driver is seated on the crane driver's seat.
Turn the ignition off.
Start the engine again.
If the engine still cannot be started:
Watch the indicator lights 652 on the BKE 650.
Note
For problem remedy, see Crane operating instructions, chapter 4.03.

2.3 Have the hydraulic, electric or engine failed?

Note
Is the equipment for hydraulic emergency control part of the scope of delivery, the crane can be
taken down when the crane hydraulic, crane electric and crane engine failed.
For emergency control, see Crane operating instructions, chapter 6.05.
7.15 LIEBHERR 1009

B109438
1010 LIEBHERR 7.15

2.4 Bluetooth™ Terminal (BTT)

Note
Required only for cranes with Bluetooth™ Terminal (BTT).
2.4.1 The display of the BTT remains dark?
Note
The LED 552 shows the charge condition of the BTT 4.
If the LED 552 does not light up after turning the BTT 4 on:
Plug the BTT into the charging module.
If the LED 552 does not light up after plugging the BTT 4 into the charging module:
2.4.2 Is the radio connection faulty?

If the radio contact connection to the BTT 4 is faulty or interrupted, then it can be bypassed with
line 20.
The radio contact connection to the BTT 4 can become faulty or interrupted by the following
occurrences:
– Through interference signals from a nearby radio tower
– The radio module on the BTT 4 or on the BTB is defective.
– The rechargeable battery in the BTT 4 is discharged.
– Due to bad selection of location by the operator
Bypassing the radio connection

– The line 20 to bypass the radio connection has been removed from the switch cabinet of the crane
cab.
– The BTT 4 has been removed from the charge module 22 and is turned on.
– The caps on the plug connection 23 and the plug connection 29 have been removed.
Screw the line 20 on the charge module 22 onto the plug connection 23.
Screw the line 20 on the BTT 4 onto the plug connection 29.
Continue operation with the BTT 4.
Note
If the BTT 4 does not turn on, even though the line 20 is connected with the charge module 22, then
the rechargeable battery may be defective!
7.15 LIEBHERR 1011

B110963
1012 LIEBHERR 7.15

2.5 LICCON monitor
2.5.1 Error identification on LICCON computer system
Note
For error identification on the LICCON computer system, see Operating instructions Diagnostics,
chapter 20.05.
Procedure in case of error messages with LEC

Two different types of errors are differentiated with the LEC:
– Operating errors - Error code starts with a “B”.
– System errors / application errors - Error code starts with an “E”.
If an error code starts with a “B”:
Correct the operating error.
If an error code starts with an “E”:
Call up the test system, see Operating instructions Diagnostics, chapter 20.05.
2.5.2 Did an alarm function occur?
Note
For a detailed description of alarm functions, see Crane operating instructions, chapter 4.02.
In case of an alarm function, an error message 7 with LICCON error code appears at the same
time.
The following alarm functions are indicated by blinking icons on the LICCON monitor 0:
– Boom limitation 3
– Hoist top limit switch 4
– Advance warning load 5.1 / Advance warning engine 5.2
– Stop load 6.1 / Stop engine 6.2
The limit ranges of the crane movements are monitored by:
– Hoist limit switch
– Angle sensors
– Pressure sensors
– Length sensors
– Wind sensor
– Inductive sensors
If the limit ranges for these sensors are exceeded, the crane movements are turned off (LMB-STOP).
The load moment limiter (LML) is a program of the LICCON computer system to monitor the
permissible load moment. If the permissible load moments of the load chart are exceeded, the
LMB-STOP turns the crane movements off.
Note
In case of certain shut offs, you can only continue to work by bypassing the safety devices.
7.15 LIEBHERR 1013

B110963
1014 LIEBHERR 7.15

WARNING
Risk of accident!
All instructions and data in the Crane operating instructions, chapter 4.04 must be observed and
adhered to!
WARNING
Bypassing the overload protection!
If the overload protection is bypassed, there is no further protection against crane overload!
can topple over!
It is only permitted to bypass the overload protection for assembly or in emergencies!
The bypass may only be carried out by persons who are aware of the effects of their acts
regarding the bypass of the overload protection!
Bypassing the overload protection requires the presence of an authorized person and must be
performed with utmost caution!
Crane operation with bypassed overload protection is prohibited!
If a LMB-STOP occurs due to boom limitation:

Carry out load moment reducing crane movements.
2.5.3 LICCON computer system shows an error message?
WARNING
Risk of accident!
The crane can be severely damaged or destroyed!
adhered to!
Example of an error message:

– During operation with LICCON Error Code (LEC), see Operating view illustration, example 7.
Differentiation of errors in crane operation:
– Errors which lead to shut down: The shut off icon is shown.
– Errors which do not lead to shut down: The crane operator is warned.
7.15 LIEBHERR 1015

B110963
1016 LIEBHERR 7.15

2.6 Does the touch display remain dark?

If the Touch display 460 does not turn on after turning the ignition on:
2.7 Is telescoping not possible?

Note
Only required for cranes with Telematic.
If telescoping is not possible, then the telescoping lock may be defective.
WARNING
Increased danger of accidents in case of defective telescoping lock!
There is an increased risk of accident if the following danger notes are not observed!
“Emergency control telescoping” may only be carried out by authorized expert personnel trained
on Liebherr-Werk Ehingen mobile cranes, who know the dangers of emergency operation!
It is imperative that the next Liebherr Service location or Liebherr-Werk Ehingen is contacted!
All crane movements must be carried out with extreme caution!
Telescoping must be constantly monitored by a second person!
2.7.1 How is the error recognized?

– Telescoping is not functioning.
Possible causes:
– The valves are mechanically defective.
– The electrical connection is interrupted.
– The valves can no longer be supplied with power.
7.15 LIEBHERR 1017

B110963
1018 LIEBHERR 7.15

3 Carry out error diagnostics

Several possibilities exist for an error diagnostics:
– With the help of Liebherr Service
– With the help of Liebherr Service via remote diagnostics
– Without the help of Liebherr Service
3.1 Error diagnostics with the help of Liebherr Service
3.1.1 Error diagnostics by phone

3.1.2 Remote diagnostics

The remote diagnostics makes it possible for Liebherr Service to check Liebherr cranes from a remote
location in case of problems.
Activation of the remote diagnostics device is first carried out by Liebherr Service.
– The crane operator has a valid SIM-card (telephone card for mobile telephones) from a current
mobile network operator.
– The telephone number of the data service is known.
– The PIN code request of the SIM-card is deactivated.
– The SIM-card is installed in the GSM module.
– Follow the instructions given by Liebherr Service.
Note
For information for remote diagnostics, see Operating instructions Diagnostics, chapter 20.15.
3.2 Error diagnostics without the help of Liebherr Service

WARNING
Measures without the help of Liebherr Service!
Measures in case of a problem, which are carried out without consulting Liebherr Service can cause
damage to the crane. Personnel can be severely injured or killed!
If problems remain or in case of error messages, consult Liebherr Service to determine the cause
of the problem and further procedure.
Note
For information for remote diagnostics, see Operating instructions Diagnostics, chapter 20.15.
7.15 LIEBHERR 1019

B110960
1020 LIEBHERR 7.15

4 Measures for defective components
WARNING
Danger to life if original attachment parts are not used!
If the crane is operated with attachment parts, which are not original, then the crane can fail and
cause fatal accidents!
Crane components can be damaged!
Operate the crane only with original attachment parts!
Crane operation with attachment parts, which do not belong to the crane is prohibited!
WARNING
The crane permit and the manufacturer's warranty will become void!
If any original installed parts are modified, manipulated or replaced (e.g. removal of parts, installation
of non-original Liebherr parts), both the crane permit and the manufacturer's warranty will become
void.
Leave installed original parts unchanged!
Do not remove installed original parts!
Use only Original Liebherr spare parts!

– Error diagnostics has been carried out.
– Defective component has been determined.
4.1 Is the LICCON monitor defective?

Replace the LICCON monitor 324 with a functioning substitute monitor.
Note
For instructions to change a defective LICCON monitor 324, see Operating instructions
Diagnostics, chapter 20.15.
4.2 Is the power supply defective?

Replace the power supply with a functioning power supply.
Note
For instruction of replacement of a defective power supply, see Operating instructions,
4.3 Is the central processing unit defective?

Replace the CPU with a functioning CPU.
Note
For instruction of replacement of a defective power supply, see Operating instructions,
7.15 LIEBHERR 1021

B110964
1022 LIEBHERR 7.15

4.4 Is the electrical connection of a cable drum interrupted?

WARNING
Interrupted electrical connection!
If the electrical connection of a cable drum is interrupted, then this causes a shut off (LMB STOP). No
further crane movements are possible.
Contact Liebherr Service to determine further procedure.
4.5 Is a sensor defective?
4.5.1 General
Certain crane functions are monitored with two sets of sensors.
Note
For double version: If only one of the two sensor is defective, then work can continue with the
crane.
Replace the defective sensor.
Note
For single version: If a sensor is defective, then this causes a shut off (LMB STOP).
For double version: If both sensors are defective, then this causes a shut off (LMB STOP).
4.5.2 Possible sensor defects

The following sensor defects can occur:
– Length sensor defective, see illustration A.
– Angle sensor defective, see illustration B.
– Pressure sensor defective, see illustration C.
4.5.3 Length sensor defective?

If illustration A is shown on the LICCON monitor, then the length sensor is defective:
Carry out error diagnostics via the BSE test system, see Operating instructions, Diagnostics,
chapter 20.10.
7.15 LIEBHERR 1023

B110964
1024 LIEBHERR 7.15

4.5.4 Angle sensor defective?

If illustration B is shown on the LICCON monitor, then the angle sensor is defective:
chapter 20.10.
4.5.5 Pressure sensor defective?

If illustration C is shown on the LICCON monitor, then the pressure sensor is defective:
chapter 20.10.
4.6 Is a limit switch defective?

Certain crane functions are monitored with two sets of limit switches.
Note
For double version: If only one of the two limit switches is defective, then work can continue with
the crane.
Replace the defective limit switch.
Note
For single version: If a limit switch is defective, then this causes a shut off (LMB STOP).
For double version: If both limit switches are defective, then this causes a shut off (LMB STOP).
DANGER
Bypassing the overload protection!
If the overload protection is bypassed, there is no further protection against crane overload!
can topple over!
It is only permitted to bypass the overload protection for assembly or in emergencies!
The bypass may only be carried out by persons who are aware of the effects of their acts
regarding the bypass of the overload protection!
Bypassing the overload protection requires the presence of an authorized person and must be
performed with utmost caution!
Missing values must be monitored manually and must match the load chart.
Crane operation with bypassed overload protection is prohibited!
adhered to!
7.15 LIEBHERR 1025

1026 LIEBHERR
8.00 Inspections of cranes
LIEBHERR 1027
027298-06 8.01 Periodic crane inspections
B195219
1028 LIEBHERR 8.01

8.01 Periodic crane inspections 027298-06
1 General
This crane was tested at the manufacturer's facilities prior to shipment in accordance with the latest
ISO, FEM and DIN Standards and BGV D6 (BGG 905).
The safety level achieved during initial commissioning may not be attainable during operation.
Examples of the root cause of such deviations include; e.g., wear and tear, corrosion, effects of
external forces, changes in the environment and changes to the mode of operation.
The operator is responsible for taking the necessary steps to ensure that the maximum level of safety
is maintained.
The crane operator is therefore obligated to have the crane inspected by an expert, at intervals
depending on the operational conditions but at least once per year, from the first day of vehicle
registration.
The crane must be inspected by an authorized inspector every four years after it has been licensed.
The crane must be annually inspected by an authorized inspector after its twelfth year of operation.
To ensure the high safety standard of the crane, we recommend - no later than the 12th year, in the
20th year, in the 26th year and then every 4 years - to have the crane undergo a general inspection
by an authorized inspector. At that time, in addition to the usual scope of inspection, all load carrying
parts of the crane - the complete steel structure with all welding seams as well as all components and
connecting devices - are to be subjected to a complete visual inspection. The following procedural
notes for repeat inspections are to be observed for that.
WARNING
There is a risk of weakening the supporting components when major changes or repairs are made to
the crane!
In this case, the operator must have the crane reinspected by an authorized inspector before
putting it back into service!
Respective local regulations also apply.

Expert: Is a person whose technical training and experience means that he has adequate knowledge
in the field of inspecting technical equipment. He is adequately familiar with the relevant national work
safety regulations, accident prevention regulations, and standards that he is able to evaluate the
operational safety of the equipment (for example cranes). Responsible employees from specialist
workshops and customer service engineers may be considered as experts.
Note
Experts are not authorized inspectors!
Authorized inspector: Is a person whose technical training and experience means that he has
explicit knowledge in the field of inspecting technical equipment. He is adequately familiar with the
relevant national work safety regulations, accident prevention regulations, and standards that he is
able to evaluate the operational safety of the equipment (for example cranes). He is to test the
technical equipment and is able to certify the equipment as safe. Authorized inspectors can be active
engineers.
Note
Authorized inspectors are legally recognized experts who have received special training!
The periodic inspection is principally a visual inspection, wherein the inspector / technical expert
appraises the condition of the crane and its components.
The purpose of the inspections is to avoid accidents by detecting deficiencies in a timely fashion. Any
deficiencies determined by the inspectors must be documented, remedied, and subsequently
reinspected.
A number of important examples of items that are particularly important during the periodic crane
inspections are listed in the following: We wish to advise that the authorized inspectors / experts take
sole responsibility for the crane inspections that they carry out.
8.01 LIEBHERR 1029

Note
The inspection may not be solely limited to the following positions shown in the sample
construction illustrations. Rather the entire crane structure must be subjected to a careful
inspection!
A checklist for periodic inspections recommended for Liebherr mobile and crawler cranes is included
in the appendix to assist the inspectors.
If the inspector has any questions they should be directed through our Service Department to
Liebherr-Werk Ehingen GmbH's technical departments.
WARNING
Risk of accident!
Adhere to the following inspection guidelines and intervals.
2 Inspection of carrying crane structures, especially

steel structures
DANGER
The crane structures, particularly steel constructions have to be checked by an expert or authorized
inspector at least once a year. If this is not the case, they could fail and cause fatal injury or seriously
damage the crane!
Crane structures, particularly steel structures must be checked by an expert or an authorized
inspector at least once a year!
Shorten the inspection intervals if the crane is subjected to above-average load spectrums, for
example when handling large material quantities or frequently erecting long boom systems.
If the crane was subjected to excessive operating loads; e.g., due to an unusual impact, the crane
structure, especially the steel structures must be inspected immediately!
Crane structures, especially steel structures, such as booms, turntables, chassis, support equipment
(e.g., sliding beams or folding outriggers) must be carefully inspected, at the very least during the
annual recommended crane inspections. Inspect welding seams especially through an intensive
visual inspection.
If paint damage with corrosion (rust) is found on load carrying parts of the crane structure, especially
on telescopic booms, lattice booms, lattice jibs, pull rods etc., then the rust must be removed, primed
and painted.
During an electrolyte process, such as corrosion in combination with water, an atomic hydrogen is
created, which causes to hydrogen induced corrosion with resulting cracks on high tensile fine grain
construction steel.
If disassembly and assembly work on the crane is required to carry out the inspections, then they
must be carried out by taking the manufacturer's data into account or in coordination with the crane
manufacturer.
We would like to point out that the framework of mobile cranes is designed for a limited number of
stress work cycles. This also determines the utilization or service life of the framework. The service life
is not determined solely by the number of stress cycles. It also depends on the loads (load spectrum)
applied during the time in operation.
Liebherr mobile and crawler cranes are designed for specific characteristics and movements, such as
constant deployment of drive forces, only occasional operation and load conditions according to EN
13000:2010.
Liebherr mobile and crawler cranes are designed for assembly operation and - according to
EN 13000:2010, chapter 4.1.2.1 - they can only take on a limited number of work cycles (N = 32000)
when grouping them into collective class Q1 = light (kp = 0.125).
Example of a load collective according to grouping in collective class Q1 = light (kp = 0.125).
1030 LIEBHERR 8.01

Li: Load proportion in relation to maximum load [%]

ni: Load cycles in relation to maximum number [%]
Note
The service life of Liebherr mobile and crawler cranes can be drastically reduced, for example
when used in magnet, grapple or material handling applications!
Repeated inspection of crane structure, especially the steel structure and the welding seams must
then be carried out in shorter intervals than specified.
For that reason, the steel structures and the welding joints must be subjected to an visual intensive
inspection by the expert during the specified periodic inspections.
If any damage (such as cracks or suspicion of cracks) are apparent on any part of the steel structure,
the total extent of the damage must be determined by qualified specialists using appropriate material
testing methods, such as magnetic crack detection, ultrasound or x-rays. Thereafter, the qualified
personnel must determine whether or not the damaged area can be repaired by welding or by other
means.
The following diagrams are samples of the load-bearing weld designs. The welding joints or seams or
steel structural zones that require inspection may be present more than once and in various forms.
The joints or zones must be inspected all around at the locations identified by arrows.
Note
The scope and extent of all inspections remain the sole responsibility of the inspectors!
The scope and results of tests should be documented to permit reproducibility. This
documentation forms part of the crane records and should be safely stored during the entire
service life of the crane!
The following diagrams are provided to assist the inspector. The sketches are only examples and
are not necessarily 100 % complete!
8.01 LIEBHERR 1031

2.1 Repair welds

If defects such as cracks or permanent deformation are detected on load-bearing steel components,
they should be immediately reported to Liebherr-Werk Ehingen GmbH (hereinafter called LWE),
Customer Service Department.
Furthermore, the defect must immediately be appraised by an authorized inspector in accordance with
standard welding practice rules. The inspector must immediately ascertain whether or not the crane
can continue to be safely operated until the time of the repair.
The following items apply to the repair weld:
– Repair welds may only be carried out by LWE personnel, or third party personnel contracted by
LWE, with appropriate welding qualifications according to EN 287-1 for the subject material and
welding method!
– The repair weld must be carried out in accordance with the latest revision of LWE's internal
welding guideline ISR B 010!
– The repaired structural component must subsequently be subjected to a load test.
The required test loads and boom configurations are to be determined by LWE Service!
Successful test results are to be documented in the crane inspection log!
– We also refer to observing the accident prevention regulations “Principles for testing cranes by
authorized inspectors or experts in accordance with UVV Cranes BGV D6 and BGG 905”!
WARNING
Danger of accidents in case of defective repair welds!
Due to defective repair welds, severe personnel and property damage can result!
Observe and adhere to the instructions and welding regulations!
Note
Exclusion of liability!
For repair welds, which are not made by LWE personnel or by personnel authorized by LWE,
Liebherr-Werk Ehingen GmbH excludes liability for the system functionality as well as for the parts!
Have repair welds only made by LWE personnel or by personnel authorized by LWE!
1032 LIEBHERR 8.01

blank page!
8.01 LIEBHERR 1033

B185046 Example for vehicle frame
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8.01 LIEBHERR 1035

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B105687 Example for tow coupling
8.01 LIEBHERR 1037

B105698 Example for sliding beam
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8.01 LIEBHERR 1041

B185060 Example for slewing sliding beam
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B187347 Example for crawler center section
8.01 LIEBHERR 1045

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8.01 LIEBHERR 1047

B187348 Example for cross carrier
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B105727 Example for cross carrier
8.01 LIEBHERR 1049

B187349 Example for crawler carrier
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B185048 Example for turntable frame
8.01 LIEBHERR 1053

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B105801 Example for ballasting cylinder
8.01 LIEBHERR 1067

B105705 Example for mounting plate
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B105807 Example for base plate
8.01 LIEBHERR 1069

B185050 Example for telescopic boom
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B105891 Example for push out mechanics telescopic boom
8.01 LIEBHERR 1075

B105892 Example for boom nose
1076 LIEBHERR 8.01

B105689 Example for dolly console
8.01 LIEBHERR 1077

B185051 Example for lattice jib
1078 LIEBHERR 8.01

B185052 Example for NA / WA frame
8.01 LIEBHERR 1079

B105713 Example for end section
1080 LIEBHERR 8.01

B105836 Example for pivot section, adapter and boom nose
8.01 LIEBHERR 1081

B185058 Example for folding jib
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B105697 Example for folding jib
8.01 LIEBHERR 1083

B105732 Example for W-connector head
1084 LIEBHERR 8.01

B185053 Example for assembly unit with lattice jib
8.01 LIEBHERR 1085

B105838 Example for NA frames
1086 LIEBHERR 8.01

B185054 Example for pulley head
8.01 LIEBHERR 1087

B185055 Example for guy rod
1088 LIEBHERR 8.01

B185059 Example for TA-guying
8.01 LIEBHERR 1089

B105707 Example for TY-guying
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8.01 LIEBHERR 1091

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2.2 Inspection of lattice sections

Note
The illustration is only an example and is valid for all lattice sections!
Check all diagonal and frame pipe connections!
Example for lattice sections
8.01 LIEBHERR 1093

B107378
1094 LIEBHERR 8.01

3 Inspection of tires and disk wheels
3.1 Inspection of tires

WARNING
Risk of accident if incorrect tires are used!
The use of improper tires and tires which do not meet the license permits may result in serious
accidents with fatal injuries!
Only tire types and sizes approved for this crane may be assembled on the crane.
Regularly check the tires for damage, tread depth, foreign particles and tire pressures!
Carefully remove any foreign particles stuck or wedged in the tire tread before starting to travel (for
example: rocks or gravel)!
The tread depth of the tire may not fall below the legally specified minimum value.
– Check the tread depth.
– Check the tires for damage.
– Make sure that the tire 3 is correctly seated on the disk wheel 1. The tire bead must touch the
inside and outside of the disk wheel evenly.
WARNING
Risk of fatal injury if the lock ring 2 is not properly seated!
Personnel can be severely injured or killed due to an incorrectly assembled lock ring 2!
Check to ensure that the lock ring is correctly seated!
Consult with authorized and trained specialists if there is any doubt whether a lock ring 2 has been
correctly assembled!
Indications of an incorrectly installed lock ring are present if:

– The lock ring 2 is not completely seated with its entire circumference in the groove ( point X) of the
disk wheel, see illustration A.
– The gap of the installed lock ring 2 is outside the permissible tolerance range of 3 mm to 12 mm.
3.2 Inspection of tire pressure

– The tire 3 is correctly seated on the disk wheel.
– The lock ring 2 correctly sits in the groove ( point X) on the disk wheel, see illustration A.
– The gap on the lock ring 2 is between 3 mm and 12 mm.
WARNING
When checking the tire inflation pressure on the vehicle or after assembling tires, make sure that the
lock ring 2 is correctly installed on the disk wheel.
If the tire pressure has dropped below 3 bar and the tires are improperly inflated, there is a risk of fatal
injury if the lock ring 2 jumps off explosively.
If the tire pressure is below 3 bar, the tire may only be inflated by authorized and trained
specialists!
If the lock ring 2 is not correctly seated on the disk wheel, it is essential that authorized and trained
personnel are called in. Do not attempt to change the tire pressure yourself!
Adhere to the specified tire pressure!
The tire pressure may not exceed or fall below the permitted range, otherwise the body of the tire
could be damaged and tire failure may occur.
8.01 LIEBHERR 1095

Note
Always check the tire pressure when the tires are cold!
The specified tire pressure must be within the tolerance range of ±0.2 bar!
Observe the tire pressure, which is approved for the tire assembled on the crane. See Crane
– Check the tire pressure.
3.3 Inspection of disk wheels

The disk wheel is one of the most important safety relevant components on the vehicle.
The disk wheel is a welded steel structure and must be inspected according to section 2.
In addition, at least during the annual specified inspection of cranes, the outside and the inside of the
disk wheel must be visually inspected, taken the below listed points into account.
If cracks on the outside in the paint of the disk wheel can be seen, also recognizable by rust lines in
the paint, then the disk wheel must be inspected closely for cracks. The “color penetration
procedure” is recommended for this crack inspection.
In particular, the disk wheels must be inspected for cracks that are developing in the base material, as
well as at the locations indicated by the arrows.
Any disk wheels that show evidence of cracks or crack formation must be replaced immediately.
After a mileage of maximum 40,000 km, the operator must routinely inspect the disk wheel regardless
of the actual load spectrum.
The following safety and maintenance guidelines are the manufacturer's recommendations for
avoiding safety risks caused by damaged disk wheels. In addition, the manufacturer can only provide
a warranty in case of a claim if these guidelines have been observed.
Note
Tires may only be changed by authorized and trained specialists!
This applies both to dismounting and mounting of the tire on the disk wheel 1!
Workshop personnel or authorized and trained specialists should check the wheels at the rim and the
disk wheel for the following when changing the tires:
– Excessive rust or corrosion.
– Bent rim flanges.
– Cracks in the disk wheel.
– Cracks in the brake drum fastening on the inside or outside of the disk wheel.
– Weld seam connection on inside or outside of disk wheel.
– Damage to side and locking rings.
– Damaged wheel bolts or nuts.
– Worn out pin holes.
– Matching disk wheel parts.
WARNING
Risk of overload breakage!
Disk wheels with worn bolt holes must be scrapped immediately. Repairing these highly-stressed disk
wheel components causes structural changes in the material, which can lead to premature overload
breakage!
No welding work is permitted on rims and disk wheels, particularly repairs to worn bolt bores!
– If damaged disk wheel parts are discovered during the inspection:

Remove and replace any damaged disk wheel components.
– If paint damage or minor rust formation is found:
Recondition the wheels with commercially available paint after removing the rust. Pay special
attention to a perfect surface on the tire seating surfaces.
1096 LIEBHERR 8.01

4 Inspecting the hoist and luffing winches

The hoist and luffing winches are designed in sealed planetary gear version. These gears are sized
for long service life and the drive shafts and gears are rated for endurance.
Even though the hoist and luffing winches are designed for long life, an external visual inspection is
not adequate, since their life can be significantly affected by bad maintenance (insufficient oil), using
oil that does not meet specification requirements, defective seals, improper operation or overloading.
The annual inspection must therefore be carried out by an expert in accordance with the following
requirements.
The winches must be inspected by an authorized inspector every four years after the initial license.
Within the territorial validity of the BGV D6, after the 10th year in operation, counted from the first day
of initial license, if the theoretical utilization time is not over, the winches must be checked annually by
an authorized inspector.
4.1 Inspections
4.1.1 Inspection intervals

At least once a year, see Crane operating instructions, chapter 7.03.
4.1.2 Inspecting oil level

Re-check oil level using the dipstick.
For hoist and intake winches without a dipstick, we recommend that the oil is drained and the amount
compared to the specified oil quantity.
4.1.3 Evaluating oil color

Assume that the oil has been overheated if it is black and/or a burnt oil smell is detected. Change the
oil.
4.1.4 Checking for foreign substances

The used oil is to be dribbled on special filter fleece. Visual inspection with a magnifying glass may
reveal coarse particles. If particles are detected, all the oil's properties must be examined by a
qualified laboratory.
Note
The evaluation of the foreign particles found in the oil must be made by a qualified laboratory!
The maximum permissible quantity of foreign material measured by weight is 0.15 % of total oil
weight!
Maximum permissible foreign particle size from fine abrasion is 0.25 microns!
If the above value have been exceeded, remove the gear and search for the cause of the
increased abrasion!
Damaged components must be replaced and the gear refilled with fresh oil!
NOTICE
Repairs may only be carried out by specialists with appropriate technical knowledge!
4.1.5 Visual inspection for leaks

The gears must be checked for leaks, since loss of oil, in addition to polluting the environment, can
lead to gear failure.
8.01 LIEBHERR 1097

4.1.6 Inspecting the gear brakes

Check the brakes each time the gears are inspected.
Proceed as follows:
– Attach a load, which creates the maximum rope pull in the uppermost layer of the coil and raise it
just off the ground.
– Remove the plug on the brake vent magnet.
This causes the brake to remain engaged when operated.
– Operate the winch to lower it.
Note
The brake should not slip, i.e. the winch should not turn. If the brake slips, contact the Service
department at Liebherr-Werk Ehingen GmbH!
Only operate the crane after it has been checked and approved for use by the Service department
at Liebherr Werk Ehingen GmbH!
NOTICE
Only qualified personnel with specialized knowledge may be used to evaluate gears and brakes!
4.1.7 Documenting the completed inspection and tests

The results of the annual inspections and maintenance work, including the steps taken, must be
documented by the competent or authorized inspector, including attachments from the inspection labs
and qualified service companies if applicable.
This documentation must be filed in the crane inspection log under the heading "Periodic inspections".
4.2 Requirements for monitoring the winches
4.2.1 Theoretical service life

The designer of your crane used a theoretical total operating time when designing and sizing the
winches. This resulted in the theoretical service life of the equipment.
The winches of your crane are classified according to ISO 4301/1 as follows:
Winches Classification
Power train group: M3
Load spectrum: L1
Load spectrum factor Km: 0,125
Theoretical service life D: 3200 h
1098 LIEBHERR 8.01

Note
The “theoretic service life” is not equal to the real (true) service life of a winch!
The true service life of the winch is affected by many additional outside factors; for example:
– Overloads caused by unapproved use of the crane.
– Inadequate maintenance: Oil is not changed in a timely manner.
– Improper operation:
• Extreme acceleration or deceleration of the load.
• Load falling into the ropes.
– Improper maintenance:
• Using the wrong type of oil.
• Too much or too little oil.
• Contamination during oil change.
– Assembly errors during repair and maintenance.
– Undetected leakage.
– Incorrectly set safety devices.
– Hidden damage from accidents.
– Extreme environmental conditions:
• Extreme low or high temperatures.
• Corrosive atmosphere.
• Dust and dirt.
4.2.2 Actually used part of the Service life

The crane operator is obligated to carry out an inspection of the crane at least once a year.
At this time, the actually used part of the theoretical service life must also be calculated. If necessary,
the crane operator must contract an authorized inspector.
For the determination of the used part of the theoretical service life, the actual operating conditions
(load spectrum) and the hoist gear operating hours for each inspection interval are to be determined.
The operator is responsible for the documentation in the crane inspection log.
Determining the operating conditions (load spectrum)
The load spectrum of the crane is divided into groups, please refer to ISO 4301/1.
Select one of the following load spectrums and record it in the crane inspection log for the respective
inspection interval based on the actual operating conditions. A more precise determination of the load
spectrum is permissible.
Load spectrum class: Light L1
Definition:
Power train or parts thereof are subjected to maximum stress only in exceptional cases, but normally
only operate at very light loads.
Operating time rates:
10 % of the time at maximum load (dead load and 1/1 working load)
40 % of the time with dead load and 1/3 working load
50 % of the operating time, with dead load only
Factor of load spectrum:
Km = 0.125
Graphic view:
8.01 LIEBHERR 1099

Note
Load spectrum L1 with load spectrum factor Km = 0.125 is normally applied to cranes used for
assembly operations!
Load spectrum class: Medium L2

Definition:
Power train or parts thereof are subjected to maximum load relatively often, but normally only operate
at light load.
1/6 of the time at maximum load (dead load and 1/1 working load).
1/6 of the time with dead load and 2/3 working load.
1/6 of the time with dead load and 1/3 working load.
Km = 0.25
Graphic view:
Load spectrum class: Heavy L3

Definition:
Power train or parts thereof are frequently subjected to maximum load and normally operate at
medium load.
Km = 0.5
Graphic view:
1100 LIEBHERR 8.01

Load spectrum class: Very heavy L4

Definition:
Power train or parts thereof are regularly subjected to near maximum load.
Km = 1
Graphic view:
8.01 LIEBHERR 1101

Determining the effective operating hours Ti

The effective operating hours calculated as follows must be entered into the crane inspection log for
the respective inspection interval.
There are four different scenarios:
1.) Operating hour meter installed on every winch.
If an operating hour meter is installed on every winch, the effective operating hours Ti can be read
directly during each inspection.
2.) Operating hour meter installed for the overall crane drive.
The winch proportion of the total superstructure operating hours must be estimated.
For cranes used in assembly operations, the operating time for the hoist winches can be
estimated at 20 % in relation to the total operating hours of the superstructure.
3.) One operating hour meter is used for both the crane engine and the crane drive.
The winch proportion of the total crane operating hours must be estimated.
For cranes used in assembly operations, the operating time for the superstructure can be
estimated at 60 % of the total operating hours of the crane. If the hoist winch proportion is
estimated at 20 % of the superstructure operating hours (see previous item), then the result in
relation to the total operating hours of the crane is: 12 %.
4.) No operating hour meter installed.
In this case the operator must estimate and document the actual operating hours of the winch.
The approximate percentages stated above normally apply to main hoist winches. For auxiliary
hoist winches or boom control winches, the proportion of the total operating hours can be
significantly less and should therefore be estimated by the operator.
Determining the used proportion of the theoretical service life

For an inspection interval i (max. 1 year), the actually used proportion Si of the theoretical Service life
is derived from the formula:
Abbreviation Explanation
Si Used proportion of the theoretical service life.
Km Load spectrum factor that was used to calculate the winch rates. This factor is
provided in the Operating instructions.
Kmi Load spectrum factor for inspection interval i according to section “Determining
the operating conditions” .
Ti Effective operating hours for inspection interval i according to section
“Determining the effective operating hours Ti ” .
The actually used proportion is subtracted from the remaining theoretical service life Di after each
inspection interval (see example).
If the remaining theoretical service life is not long enough to cover the next projected operating period,
a general overhaul of the winch is required.
1102 LIEBHERR 8.01

If the theoretical service life D has been reached (see chapter on “Theoretical service life”), then the
winch may only be operated after conducting a general overhaul.
A general overhaul of the winch is required not later than 10 years after commissioning.
The general overhaul shall be arranged by the operator and carried out by the manufacturer or the
manufacturer's authorized representatives and must be documented in the inspection log. After the
general overhaul, the manufacturer or the manufacturer's authorized representative will define a new
theoretical service life D.
If the theoretical service life has not been reached after 10 years, continued operation of the winch
without a general overhaul is acceptable, provided that the crane's authorized inspector has confirmed
the accuracy of the actual usage calculation by signing the crane inspection log at each authorized
inspection interval.
In such a case, the crane authorized inspector must thoroughly inspect the winch. This comprises at
least:
– External visual inspection (leakage, damage, deformation, etc.).
– Oil check, especially for metal residues.
– Load test at minimum and maximum rope tension and at maximum possible speed in both cases.
At least one layer must be spooled up. Pay particular attention to any unusual noises during this
load test.
The crane's authorized inspector must confirm this inspection in the crane inspection log and must
make a statement regarding suitability of the winch for continued operation. The next inspection must
take place at the end of the 12th operating year and annually thereafter.
4.2.3 Example
According to the manufacturer's operating manual, a mobile crane with a separate operating hour
meter for the crane engine and the crane drives classified as follows:
– Power train group: M3
– Load spectrum: Light L1
– Factor of load spectrum: Km = 0.125
– Theoretical service life: D = 3200 h
Actual usage proportion S of the theoretical service life is calculated using the individual inspection
intervals as follows:
First inspection (first year)
The crane was used for assembly work during the elapsed year:
Load spectrum L1, in other words Km1 = 0.125.
The superstructure hour meter indicates 800 h. The winch was operated about 20 % of the time; i.e.
T1 = 160 h.
The actual usage proportion S of the theoretical service life at the time of the first inspection is
therefore:
Remaining theoretical service life:

D1 = 3200 h – 160 h = 3040 h
The above values are recorded in the crane inspection log.
Second inspection (second year)
The crane was used at a harbor for unloading work:
The superstructure hour meter indicates 2000 h; i.e., during this period:
2000 h – 800 h = 1200 h (800 h were used in the first year of operation)
The winch was operated about 40 % of the time; i.e. T2 = 480 h.
The actual usage proportion S2 of the theoretical service life at the time of the second inspection is
therefore:
8.01 LIEBHERR 1103


D2 = 3040 h – 1920 h = 1120 h
Third inspection (third year)
The crane was used for assembly work and occasionally at a harbor for unloading work:
The superstructure hour meter indicates 3000 h; i.e., during this period:
3000 h – 2000 h = 1000 h (2000 h were used in the first two years of operation)
The winch was operated about 30 % of the time; i.e. T3 = 300 h.
The actual usage proportion S3 of the theoretical service life at the time of the third inspection is
therefore:

D3 = 1120 h – 600 h = 520 h
4.2.4 Table for theoretically determining the remaining service life

Table 1 includes an example.
The theoretical remaining service life should be documented in table 2.
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B102588
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B102589
8.01 LIEBHERR 1107

B195239
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5 Inspecting load hooks

The load hooks must be visually inspected annually by a competent inspector.
This inspection must be carried out by an authorized expert every 4 years.
The purpose of the inspections is to avoid accidents by detecting deficiencies in a timely fashion.
Any deficiencies determined by the inspector must be documented, corrected, and subsequently
reinspected.
5.1 Inspection and monitoring procedure
5.1.1 Deformation
The hook should be inspected for distortion as required, but at least once a year; e.g., at the hook jaw.
The original dimensions, (y) or (y1) and (y2), are given on the load hook itself.
Measure between the punch marks.
DANGER
Risk of accident!
Hook jaw expansion may not exceed 10 % of the original dimensions (y) or (y1) and (y2)!
Do not use a load hook that exhibits greater expansion!
Contact the Service department at Liebherr-Werk Ehingen GmbH!
5.1.2 Corrosion
DANGER
Risk of accidents caused by thread corrosion / wear and tear!
Stop using the load hook!
Contact the Service department at Liebherr-Werk Ehingen GmbH!
Unscrew the nut from the hook shank every 4 years so that the threads can be inspected for corrosion
and wear by the inspection through an authorized expert.
6 Inspecting the rope feed mechanics in the

telescopic boom
– For inspection of rope end mounts, see Crane operating instructions, chapter 7.05.
– For inspection of the pre-tension on the intake ropes, see Crane operating instructions, chapter
7.05.
– For inspection of ropes for damage according to DIN 15020 or ISO 4309, see Crane operating
8.01 LIEBHERR 1109

B109286
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7 Inspection of locking system of telescopic boom
7.1 For cranes with pneumatic boom locking system

– For inspection of function, see Crane operating instructions, chapter 8.11.
– For inspection of pin wear pattern, see Crane operating instructions, chapter 8.11.
– For inspection of wear, see Crane operating instructions, chapter 8.11.
– For inspection of safety control, see Crane operating instructions, chapter 8.11.
7.2 For cranes with telescopic boom system Telematik

– Inspection of the pull knob safety 1 and all mounting screws 2 for tight seating
– Inspection of twist guards of cylinder pinning 3 and the telescopic boom pinning 11
– Inspection of the length sensor rope 4 for damage
– Inspection of the cylinder barrel in the area of all welding seams 5 for crack formation
– Inspection of the locking pockets 6 for damage
– Grease the guide rail 7
– In case of leakage: Inspection of the piston rod 8 for grooves
– Inspection of the wear pattern on the cylinder pinning 3 and the telescopic boom pinning 11
– Inspection of guide rail 7 for distortion of contour
– Inspection of plastic guide 9 on cylinder bottom for damage
– Inspection of all mounting screws 10 on the push out cylinder for tight seating
8 Inspection of membrane accumulator

Note
The national regulations for pressurized container inspection must be observed!
The inspection of the membrane accumulators for specified gas pressure must be carried out by
authorized and trained expert personnel, see Crane operating instructions, chapter 7.04, 7.05.
9 Inspection of relapse cylinders

9.1 Check the relapse cylinders for visible defects
WARNING
Defective relapse cylinders!
The relapse cylinders can be damaged due to loss of oil or corrosion and a safe crane operation can
no longer be ensured! This could result in serious accidents!
Before any operation, visually check the relapse cylinders for leaks, damage and corrosion!
If any defects are found, the relapse cylinders must be inspected by the cylinder manufacturer!
9.2 Checking the gas pressure and oil fill
9.2.1 Checking the gas pressure
Note
The gas pressure may only be checked by an expert for pressurized containers!
8.01 LIEBHERR 1111

9.2.2 Check the oil quantity
Note
The oil fill may only be checked by an expert for pressurized containers!
10 Inspection of the safety controls on the relapse

cylinders
For inspection of the safety control or limit switches on the relapse cylinders and the boom A-frames,
see Crane operating instructions, chapter 8.12.
11 Inspecting the cable pulleys

DANGER
Risk of accident when damaged or cracked!
Replace rope pulley immediately!
Inspect the rope pulleys all around once a year for damage and cracks.
If rope pulleys are subjected to any impacts (e.g., with buildings) or are otherwise overloaded, they
must be immediately visually inspected for damage or cracks.
Also check for wear in the rope groove. Replace the pulley if the bottom of the rope groove has been
run down up to 1/4 of the rope diameter.
12 Inspecting the function of the overload protection

Position the longest boom at minimum and maximum radius: Check the load indicator, using the hook
block as a test load.
The indicator reading shall not deviate more than 10 % off the true load value at these two extreme
positions.
Measure the indicated radius for the longest boom at its minimum radius and at a boom angle of 45°.
The indicator reading may not deviate more than 10 % off the measured projection.
13 Inspecting the roller ring connection

For tilt play dimension, see Crane operating instructions, chapter 7.05.
14 Inspecting the mounting of the load bearing

equipment
Check that the mounting bolts for the roller ring connection, winches, slewing gears and towing hitch
are properly seated.
Slewing ring connection mounting bolts are pre-stressed at the factory, so that no loosening of the
bolted connections will occur during normal crane operation.
However, the bolted connection may become overloaded and the bolts may be permanently stretched
if the crane is overloaded or if the load is pulled free. It is therefore important to check these screws
for tight seating during the annual crane inspection or after an overload.
Completely remove loose screws, plus the two adjacent ones on the left and right hand side and
check them immediately for damage. Inspect the screws, particularly for cracks or permanent
distortion. If a screw has been stretched by more than 0.2 % (in relation to its original length) or if
cracks or other damage are detected, then the damaged screws must be replaced. If the screws have
been stretched or there is other damage, then the adjacent screws must also be replaced.
1112 LIEBHERR 8.01

blank page!
8.01 LIEBHERR 1113

B109096
1114 LIEBHERR 8.01

15 Inspection of the tele extension with eccentric,

illustration 1
– Inspection of twist guard 1 for damage and loose screw connection
– Inspection of rotator 2 for easy turnability
– Inspection of all clamps 3 for damage and function
16 Inspection of change over pulleys, illustration 2

– Inspection of twist guard 4 for damage and loose screw connection
– Inspection of rotator 5 for easy turnability
17 Inspecting the oil and fuel reservoirs

Visually check the oil and fuel tanks at least once a year for leaks and safe mounting.
Repairs shall only be carried out by trained and knowledgeable specialists.
Improper repairs; e.g., welding, hard or soft soldering is not permitted, particularly if the Service
department at Liebherr-Werk Ehingen GmbH has not been consulted!
18 Inspection of the auxiliary reeving winch, towing

winch and spare wheel winch
Determine the service life of the auxiliary reeving winch, recovery winch and spare wheel winches
from their respective original manufacturer.
8.01 LIEBHERR 1115

19 Appendix
The following is a checklist to assist the inspector during the periodic inspections of Liebherr mobile
and crawler cranes.
19.1 Inspection recommendations for periodic inspections of Liebherr

mobile and crawler cranes
Company: Inspector:
Crane manufacturer: LIEBHERR Crane type:
Serial number: Stock number:
Construction year: Date:
Inspector's signature for No. 1 to 22:
1. Inspection category: Crane document

Component inspected A B C D E Comments
Crane inspection log
Operating and installation instructions
Crane control log
Load chart manual
Job planner
2. Inspection category: Signs / identification

Factory tag
Load data
Operating specifications label
Prohibition and command signs
Other safety signs
3. Inspection category: Travel gear1

Frame2
Supports3
Axles
Wheels
1116 LIEBHERR 8.01

3. Inspection category: Travel gear1

Tires
Bearings
Gear
Universal drive shaft
Flat springs / springs
Shock absorbers
Steering
Brakes
Hydraulic axle suspension
4. Inspection category: Chassis1

Coverings
Treads
Counterweight holders2
Suspension equipment
Ladders
Hook block mounting2
Boom support2
5. Inspection category: Chassis - driver's cab1

Doors
Windows / windshields
Windshield wipers
Mirrors
Seat
Heater
Ventilation
Sound-proofing
Trip recorder
First aid kit
8.01 LIEBHERR 1117

5. Inspection category: Chassis - driver's cab1

Spare bulbs
Hazard warning triangle
Safety vest
6. Inspection category: Chassis - drive1

Combustion engine
Exhaust system
Fuel tank
Filters
Sound-proofing
Engine mount
Oil levels
Fuel lines
7. Inspection category: Chassis - hydraulics1

Oil reservoir
Filters
Pumps
Motors
Valves
Lines
Hoses
Cylinder
Pressure limiting valves
8. Inspection category: Chassis - pressurized air system1

Compressor
Filters
Air tanks
Valves
1118 LIEBHERR 8.01

8. Inspection category: Chassis - pressurized air system1

Lines
Hoses
Cylinder
9. Inspection category: Chassis - electrical system1

Motors
Generators
Battery
Switch
Lines
Fuses
Resistors
Lighting
Brake lights
Indicator lights
Tail lights
Working lights
Signaling systems
Indicator lights
Battery switch
Limit switches: Transmission, steering,
drive train
Support pressure indicator2
10. Inspection category: Chassis - control devices1

Engine regulation
Gear
Couplings
Circuits
Brakes
Steering
Indicator displays
Engine shut off line
8.01 LIEBHERR 1119

10. Inspection category: Chassis - control devices1

Control of supports2
Axle suspension
Crane leveling
Rear axle steering
11. Inspection category: Superstructure

Frame
Coverings
Treads
Bearings
Counterweights
Relapse retainer
Rotary connection: Tilt play
Rotary connection: Mounting screws
Rotary connection: Gearing
Slewing gear: Mounting screws
Slewing gear: Gearing
12. Inspection category: Superstructure - crane operator's cab

Doors
Windows / windshields
Windshield wipers
Mirrors
Seat
Heater
Ventilation
Sound absorber
Joystick for working functions
Gear shifts
Safety: Crushing / shear locations
1120 LIEBHERR 8.01

13. Inspection category: Superstructure - Retaining and protection devices

Grab handles and accesses To the cab and to the power train
Coverings
Covers
Hatches
14. Inspection category: Superstructure - drive train

Combustion engine
Exhaust system
Fuel tank
Filters
Sound-proofing
Engine mount
Fuel lines
15. Inspection category: Superstructure - hydraulic system

Oil reservoir
Filters
Pumps
Motors
Valves
Lines
Hoses
Cylinder
Pressure limiting valves
Lowering brake valves
Brake control: Hoist gear
Brake control: Slewing gear
8.01 LIEBHERR 1121

16. Inspection category: Superstructure - electrical system

Motors
Generators
Batteries
Switch
Lines
Fuses
Resistors
Lighting
17. Inspection category: Superstructure - control systems

Engine regulation
Gear
Flexible couplings
Circuits
Engine shut off line
Monitoring indicators
18. Inspection category: Superstructure - rope drives

Winch 13
Winch 23
Winch 33
Winch 43
Rope pulleys
Rope end connection
Rope for winch 1
Rope for winch 2
Rope for winch 3
Rope for winch 4
Guy ropes
1122 LIEBHERR 8.01

19. Inspection category: Superstructure - load hook

Pulleys
Rope guards on pulleys
Axle support
Load hook
Load hook mounting
Hook retention
20. Inspection category: Superstructure - safety and switch systems

Hoist emergency limit switch I
Hoist emergency limit switch II
Lowering emergency limit switch I
Lowering emergency limit switch II
Boom emergency limit switch I
Boom emergency limit switch II
Luffing jib: Boom limit switch I
Luffing jib: Boom limit switch II
Load moment limiter
Angle display: Boom
Angle display: Luffing jib
Angle display: Slewing gear
Safety devices: Control
Operating range limiter
Pressure sensors
Speed sensor
Wind sensor
Sliding beam monitoring
Support pressure indicator
Incline display
Length indicator: Radius, boom length
Emergency off system
Engine stop
8.01 LIEBHERR 1123

21. Inspection category: Boom

Weld structure
Rope pulleys
Luffing cylinder
Telescoping cylinder
Boom extension ropes
Boom retraction ropes
Boom bearings
Boom pinning
Guy rods
Relapse cylinders
22. Inspection category: Equipment

Weld structure
Rope pulleys
Relapse cylinder
Relapse support
Oscillation guard
A-frame bearings
Pinning of components
Guy rods with pinning
Rods with guide rail on A-frame 2 and
A-frame 3
All limit switches with switch mechanism
Inspection criteria:
A = Present / complete
B = Condition / maintenance
C = Function
D = Repair / replace
E = Reinspection required
1124 LIEBHERR 8.01

Evaluation:
Satisfactory = x
Unsatisfactory = -
Not required = 0
Comments:
1 Inspection of the crane carrier vehicle road worthiness is also fulfilled if it has already been certified
by the road traffic department certification authority. For cranes that are not certified for use on public
roads, an expert or authorized inspector must conduct the required tests to validate the vehicle's road
worthiness.
2 These inspections must be carried out by an authorized inspector even if it has passed the road
traffic department test and is certified.

3 Inspection of the winches regarding the used portion of the theoretical service life.
8.01 LIEBHERR 1125

027299-05 8.04 Inspection of crane wire ropes
B195219
1126 LIEBHERR 8.04

8.04 Inspection of crane wire ropes 027299-05
1 Introduction
DANGER
Danger of fatal injury due to defective crane ropes!
Please observe the following criteria.
The rope should be considered to be a wear part, which must be replaced if the inspection shows that
its strength has reduced to such an extent that continued use may be dangerous.
Regular inspection of the rope is required in order to safely carry loads with correctly deployed
equipment, meaning that the rope must be taken out of service at an appropriate point in time.
The take-down criteria with regard to wire breaks, wear, corrosion and deformation can be applied
immediately under all application conditions. The different factors are dealt with in ISO 4309, which is
intended to serve as a guideline to competent experts who are involved in the maintenance and
inspection of cranes.
We recommend to carry out an annual inspection by an expert according to the following standard
(ISO 4309).
The ropes should be inspected every 4 years by an authorized inspector.
The scope of the inspection and the inspection results must be traceably documented, see addendum
2. This documentation must be retained as part of the crane records!
The criteria that are covered here are intended to provide an appropriate safety margin for movement
of loads with cranes until the rope is taken down.
2 Wire rope
2.1 Condition before installing
The rope is usually replaced with a rope that is of the same type as the original. If the spare rope is of
another type, then the user must ensure that the rope characteristics are at least as good as those of
the rope that was taken down.
Before installing a new wire rope, the grooves of the rope drums and pulleys must be checked in
order to ensure that the spare ropes is placed correctly in the rope grooves (see section entitled
“Inspection”).
2.2 Installation
When the rope is removed from the spool or unwound from a reel, it must be ensured that the rope is
not twisted, otherwise loops, reverse bends or kinks could originate in the rope.
If the rope is looped over any part of the system when it is not under strain, these areas must be
protected accordingly.
Before starting to use the rope on the system, the user must ensure that all components that are
functionally associated with the wire rope in connection with the standing components have been set
up in such a way that they will operate correctly.
To stabilize the wire rope, a few lifting procedures should be carried out at approximately 10 % of the
normal load.
2.3 Maintenance
The maintenance of the wire ropes depends on the type of lifting device, its application, the
environment as well as the type of rope that is used. Unless other instructions from the crane or rope
manufacturer are provided, the wire rope should be cleaned, if possible, and lubricated with grease or
oil, particularly in areas in which the rope is subjected to bending when it runs over pulleys.
The kind of grease that is used must be suitable for steel ropes.
Lack of maintenance will reduce the service life of the rope, particularly if the crane is used in a
corrosive environment and if re-lubricating is not possible because of the nature of the respective
crane application.
8.04 LIEBHERR 1127

2.4 Inspection according to ISO 4309
2.4.1 Frequency
Daily inspection
If possible, all visible parts of the ropes must be checked for general wear and distortion every
working day. Special attention must be paid to the rope end connections. Any suspected changes in
the condition of the rope must be reported and the rope must be inspected by a trained expert
inspector in accordance with the section “Points to check on the rope”.
In the event that the lower rope layers on the drum are used infrequently or not at all, periodically
unwind and rewind the entire drum under pretension. A rope is most cost-effective if it is used over its
entire length. For that reason, it is recommended to use an appropriate rope length when operating
the crane over longer periods.
Note
If a rope is newly placed, then it must be pretensioned and placed with a pretension of at least
10 % of the maximum rope pull.
Special inspection as described in section “Points to check on the rope”

The rope must be checked after any events that may have led to damage to the rope and / or the rope
ends and whenever the rope is taken back into service after being taken down and then re-installed.
2.4.2 Checking the spooling behavior of the rope on the cable drum
To avoid spooling errors and associated rope damage, it is necessary to check the spooling behavior
daily. If spooling errors are determined, the rope must be reeled off until there are only 3 rope coils on
the winch. Thereafter, the rope is to be tensioned with a pretension of at least 10 % of the maximal
rope pull and then placed again.
Possible spooling errors:

– Cutting into the lower rope layers 1
– Loop formation in the lower rope layers 2
1128 LIEBHERR 8.04

2.4.3 Points to check on the rope

General
Although the entire length of the rope must be checked, particular attention must be paid to checking
the following areas:
– At the rope end points on both sides, for movable as well as fixed ropes.
– The part of the rope that runs through the block or over rope pulleys; particular attention must be
paid to parts of the rope that are on rope pulleys when under load (see appendix 1) in systems
that carry out repeated movements.
– Parts of the rope that run over a compensation pulley.
– All parts of the rope that can be subjected to wear caused by external elements (e.g. protruding
hatch surrounds).
– All parts of the rope that are subjected to the effects of heat.
– On the contact positions of the ropes when spooling up.
– Check the inside of the rope for corrosion and material fatigue.
The results of the inspection must be entered in the inspection log for the system (for typical example
see section entitled “Rope inspection log” and appendix 2).
Checking the rope in the uphill pitch zones of the rope coil for flat sections
In the cross area of the coiled up rope layers, the rope is under more strain and can therefore be
flattened. To void flat sections, the rope can be shortened on the rope drum fixed point.
If the wires in the outer braids are flattened to no more than maximum half the wire diameter:
– Shorten the rope by a length of 1/3 of the rope drum circumference and reset.
DANGER
Rope breakage!
If the following measures are not observed, the rope can break, the load can fall down and fatally
injure personnel!
Take the rope down when the take down criteria is reached, as described in section “Take down
criteria”!
Take the rope down when the wires in the outer braids are flattened by more than half the wire
diameter!
Rope suspension and connection systems - except loops

The rope must be examined at the exits of the rope suspension and connection system, since this
area is particularly susceptible to initial signs of material fatigue (wire breaks) and corrosion. The rope
suspension and connection systems must also be examined for signs of deformation or wear.
Rope suspension and connection systems with pressure sleeves must undergo the same checking,
and the sleeve must be checked for cracks in the sleeve material and possible slippage of the rope in
the sleeve.
Detachable rope suspension systems (cotters, rope clamps) must be checked for wire breaks inside
and beneath the mount or fastening; it must also be examined whether the cotters and screwed-on
rope clamps are firmly connected to the rope. This check should also ensure that the requirements of
the rope suspension and connection systems standards and procedural guidelines are complied with.
8.04 LIEBHERR 1129

2.5 Take-down criteria

The safe use of the rope is assessed in accordance with the following criteria:
1.) Number of wire breaks
2.) Broken wire nests
3.) Wire break increase rate
4.) Strand breaks
5.) Rope diameter reduction, including the reduction caused by damage to the rope core
6.) External and internal wear
7.) External and internal corrosion
8.) Deformation
9.) Damage caused by the effects of heat or arc welders
These individual factors must be taken into consideration in accordance with the relevant criteria
during all examinations. However, rope quality deterioration frequently results from a combination of
the individual factors, meaning that a worsening effect occurs that can be detected by an expert and
that influences the decision as to whether the rope has reached its rope removal limit and whether it
can continue to be used.
The checker must investigate whether the deterioration has been caused by a fault in the system; if
this is the case remedial action should be recommended before fitting a new rope.
2.5.1 Number of wire breaks

The number of wire breaks must be determined by visually inspecting the entire length of the rope. If a
wire break is found, sections that are 30 × d (d = nominal rope diameter) in length are marked at both
sides of this point. These sections must be examined extremely carefully. All wire breaks are now
carefully counted in each section. Please compare the number of visible wire breaks with appendix 4.
If the number of visible wire breaks is less than the number specified in the table, the area in which
the most broken wires are found is marked to a length of 6 × d. Count the number of visible wire
breaks again and compare the result with appendix 4. If the number of visible wire breaks is less than
the number specified in the table, the rope does not have to be taken down yet.
Note
Defining the interval until the next inspection
The interval until the next inspection is set depending on the number of visible wire breaks.
2.5.2 Broken wire nests

If the wire breaks are extremely close together and form wire nests, the rope must be taken down. If
the frequency of such wire breaks occurs over a rope length of less than 6d or is concentrated on one
strand, taking the rope down is recommended, even if the number of wire breaks is less than the
maximum number specified in the tables.
2.5.3 Wire break increase rate

For applications in which the main reason for damage to the rope is material fatigue, the first wire
breaks will not occur until a certain time has elapsed, but the number of wire breaks will increase
rapidly at ever-decreasing intervals.
Careful checking and logging of the increased number of wire breaks over time is recommended in
these cases.
2.5.4 Strand breaks

If an entire strand breaks, the rope must be taken down.
1130 LIEBHERR 8.04

2.5.5 Reduction in rope diameter caused by damage to core rope

The rope diameter can be reduced as a result to damage to the core because of:
1.) Internal wear and notching
2.) Internal wear due to friction between individual strands and wires in the rope, particularly if it is
subjected to bending
3.) Steel core breakage
4.) Break in internal layers of multi-strand ropes
If the rope diameter (average of two diameter measurements) is reduced by 3 % of the nominal
diameter (rotation resistant ropes) or 10 % of the nominal diameter of other ropes due to these
factors, the ropes must be taken down, even if no wire breaks are visible.
Note
Diameter of new ropes
New ropes can have an actual diameter that is greater than the nominal diameter, meaning that
proportionally greater wear is possible.
2.5.6 External wear

Abrasion of outer wires of outer rope strands as a result of rubbing contact under pressure with the
grooves in the rope reels and drums. This condition is particularly evident in moving ropes in the
areas in which they come into contact with rope pulleys when the load is being moved and braked,
and manifest themselves as flattened surfaces on the outer wires. Abrasion is exacerbated by a lack
of or incorrect lubrication as well as the effects of dust.
Wear reduces the breaking strain of steel ropes because the cross section of the steel is reduced.
The rope must be taken down if the actual rope diameter has reduced by 7 % or more because of
outer wear, even if no wire breaks are visible.
2.5.7 External and internal corrosion

Corrosion is a particular problem in maritime climates and atmospheres that are polluted by industrial
emissions, reducing breaking strain and accelerating material fatigue because of the reduction in the
rope material cross section, leading to irregular surfaces that are the starting point for stress cracks.
Extreme corrosion can reduce the elasticity of the rope.
1.) External corrosion
Corrosion of the outer rope wires can be determined by visual inspection.
2.) Internal corrosion
This condition is more difficult to detect than external corrosion.
Note
Internal corrosion
If there are any signs of internal corrosion the rope must be checked by a competent expert.
DANGER
Occurrence of internal corrosion!
If the suspicion of extreme internal corrosion is confirmed, the rope must be taken down
immediately.
8.04 LIEBHERR 1131

2.5.8 Rope deformation

A visible change to the rope structure is referred to as “rope deformation” and can cause a change at
the deformation point that results in irregular rope tension.
A distinction is made between the following important types of rope deformation on the basis of the
rope appearance (see following sections):
1.) Corkscrew-like deformation
2.) Basket formation
3.) Strands protruding from the rope
4.) Wire loop formation
5.) Flattening
6.) Reverse bends or knots
7.) Kinks
Corkscrew-like deformation (see appendix 3, table 1)
Corkscrew-like deformation
If there is any corkscrew-like deformation the rope must be taken down if the following condition is net:
d = nominal diameter of rope

d1 = rope sheath diameter of the distorted rope
Basket formation (see appendix 3, table 2)

If there are kinks in the rope, it must be replaced immediately.
Strands protruding from the rope (see appendix 3, table 3)
The rope must be replaced immediately if this kind of deformation occurs.
Wire loop formation (see appendix 3, tables 4 and 5)
In this case, certain wires or groups of wires protrude from the rope at the side facing the rope pulley
in the form of loops - this is normally the result of sudden strain. If serious deformation occurs, the
rope must be taken down.
Flattening (see appendix 3, tables 8 and 9)
Flattening is the result of mechanical damage; if it is pronounced the rope must be replaced.
Reverse bends or knots (see appendix 3, tables 6 and 7)
If the rope has any reverse loops or knots it must be taken down immediately.
Kinks (see appendix 3, table 10)
Kinks are angled deformations in the rope caused by external influences. If there are kinks in the
rope, it must be replaced immediately.
2.5.9 Damage caused by the effects of heat or arc welders

Steel ropes that have been subjected to extremely high temperatures, which can be detected
externally because of the colouring that it causes, must be taken down.
1132 LIEBHERR 8.04

3 Operating behavior of steel ropes

Exact logging of information by the checker can be useful for predicting the behaviour of a certain type
of steel rope on a crane. This information is useful for planning and adapting maintenance instructions
and controlling the stocking of spare ropes. The use of such a prediction system should not cause the
examinations to be less strict or the rope usage time to be extended beyond the criteria that are
specified in the previous sections of this guideline for monitoring and taking down of crane ropes.
4 Condition of equipment that is functionally

associated with the rope
Note
Groove radius
The radius must not be smaller than the actual diameter of the rope.
Rope drums and pulleys must be checked at regular intervals in order to ensure that all these
components rotate correctly in their bearings. Stiff or blocked rope pulleys wear rapidly and unevenly
and cause serious rope abrasion. Ineffective compensation pulleys can lead to irregular rope tension.
The radius at the bottom of the rope grooves of all rope pulleys and the drum must be suitable for the
nominal diameter of the rope. If the radius has become too big or too small the rope groove must be
reworked or the rope pulley replaced.
5 Rope inspection log

The user must provide a log for each of the regular inspections in which all rope inspection
information is recorded. Typical example of a log - see appendix 2.
6 Rope storage and marking

Clean, dry rope storage facilities must be provided in order to prevent damage to ropes that are not in
use; it must also be ensured that the ropes can be clearly and unambiguously assigned to their
checking logs.
7 Wire ropes and rope end connections

DANGER
Risk of accident!
Correct choice and use of the wire rope and the rope end connections are a decisive precondition
for proper and accident-free crane operation.
The wire ropes and rope end connections selected in accordance with their usage. It must be
determined whether a rotation-resistant or non-rotation free rope is required. The type of rope that is
selected then determines the type of rope end connections that are used.
7.1 Rotation-resistant ropes and their rope end connections

Rotation-resistant ropes are special ropes that produce extremely little torque and twisting at the rope
end connection when they are under strain.
Note
Rotation-resistant ropes are used as hoist ropes.
8.04 LIEBHERR 1133

Typical rotation-resistant wire rope structures are ropes with 15 to 18 outer strands. Rotation-resistant
ropes are symbolically depicted with 15 outer strands (circles) (see table 1).
Rotation-resistant ropes can be optionally used with the following rope end connections:
– Rope end connection rotating in the form of a PFEIFER link with swivel or spin stabiliser / swivel.
– Rope end connection non-rotating in the form of a PFEIFER link without swivel or gib and cotter.
If possible, preference should be given to the use of a twisting rope end connection to reduce
torsional stress with rotation-resistant ropes (see table 2).
DANGER
Never use rotating rope end connections with non-rotation free ropes!
Note
Usage warning notes
The usage warning notes on the rotating PFEIFER link with pulley indicates that this rope end
connection may not be used for non-rotation free ropes (see table 3)!
7.2 Non-rotation free ropes and their rope end connections

Non-rotation free ropes generate high torque levels at the rope end connection when they are under
load. For this reason, the rope ends must be protected from twisting using an appropriate rope end
connection to prevent the rope from unscrewing under strain!
Note
Non-rotation free ropes are used as guy ropes or control ropes.
1134 LIEBHERR 8.04

Typical non-rotation free wire rope structures are ropes with 8 to 10 outer strands. Twisting ropes are
symbolically depicted with 8 outer strands (circles) (see table 4).
Non-rotation free ropes can only be used with the following rope end connections:
– Rope end connection non-rotating in the form of a PFEIFER link without swivel or gib and cotter.
A non-rotating rope end connection is also the mount of the rope on the fixed point of the winch
drum.
DANGER
Never use rotating rope end connections with non-rotation free ropes!
Never install a twist compensator / swivel!
Note
Usage warning notes
The usage warning note on PFEIFER links without swivel and cotter indicates that this rope end
connection may not be used for non-twist free ropes in combination with a twist compensator /
swivel (see table 5)!
8.04 LIEBHERR 1135

B106181
1136 LIEBHERR 8.04

8 Twisting caused by stretching in rotation-resistant

ropes and its remedy
For procedure, see illustration opposite.
WARNING
Damage to the rope!
Please proceed with extreme caution when performing the following actions.
Please heed the following instructions to the letter.
8.1 General
The cause for the turn-in of the hook block can have various reasons. For that reason, check the
crane first for the following features.
– Scrub marks: Are hoist rope scrub marks present on the crane components? If scrub marks are
present, check the hoist rope pathway and rectify.
– Rope pulleys: Has the groove diameter become too small, or do the rope pulleys exhibit a
negative profile?
• Groove diameter dimensional stability must be present.
• The rope groove must be uniformly smooth without a hoist rope negative profile.
• If this is not the case, the rope pulley must be exchanged.
– Rope greasing: Has the hoist rope been sufficiently greased? If the rope surface is dry, the hoist
rope must be re-greased.
If the crane does not display other features, the hoist rope must be spun out. Following, two methods
are described by which the hoist rope can be spun out. The methods must be applied in the described
sequence.
8.2 Turning out extremely rotation-resistant hoist ropes
8.2.1 Method 1: Spinning out with one strand reeve

1.) Reeve in the one strand hoist rope.
2.) Extend the boom to the maximal boom length and hook height.
3.) Lower hooks to approximately 1 m above the ground and allow the hoist rope to spin out.
4.) With an empty hook block, carry out one complete hoist cycle.
5.) Lower the hook again to approximately 1 m above the ground and allow the hoist rope to spin out
again.
6.) Reeve the number of strands of hoist rope carefully and spin free where the twisting of the hook
block is largest.
7.) Carry out at least two complete hoist cycles at maximum boom length and hook height, in order
to divide the spin out onto the entire rope length.
If the hook block turns in further, method 2 must be used.
8.04 LIEBHERR 1137

8.2.2 Method 2: Spin out by turning out the hook block

1.) The hook block is reeved with the largest number of strands are twisted.
2.) Extend the boom completely and lower the hook block.
3.) Attach a load of approximately 10 % of the nominal rope pull on the hook block.
4.) Before lifting the load, an assistant must carry out the following measures: Rotate the twisted
hook block to a straight position by hand until the rope strands no longer touch each other.
5.) Rotate the hook block further by a complete revolution, the rope strands touch each other again.
6.) Hold the hook block in the prescribed position until the load lifts off the ground.
• NOTICE:
When the hook block comes under load, it will attempt to rotate back to a straight position.
Release the hook block.
7.) Move the load until approximately 15 m before the uppermost hook position of the completely
extended boom.
8.) Lower load and set it down. The twisting should now be remedied.
If the hook block turns in further, then the process must be repeated. If the problem is not remedied by
this, contact Liebherr Service.
1138 LIEBHERR 8.04

blank page!
8.04 LIEBHERR 1139

B193940
A Hook block B Cable pulley C Rope drum
1140 LIEBHERR 8.04

9 Appendix 1
Diagram of possible defects, with reference to different areas that must be considered during
inspection:
1.) Check rope end connection at rope drum
2.) Examine for incorrect spooling up, which causes deformation (crushing) and wear, which can
have serious consequences at rope crossing points
3.) Examine for wire breaks
4.) Examine for corrosion
5.) Look for deformation as a result of hook block loading
6.) Inspect parts of rope that run over rope pulleys for wire breaks and wear
• Rope suspension and rope mountings:
• Check for wire breaks and corrosion
• Also inspect parts of rope that run on or next to compensating pulleys
7.) Look for deformation
8.) Check rope diameter
9.) Carefully check length of rope that runs through the hook block, particularly the part that rests on
the rope pulley under load
10.) Check for wire breaks and surface wear
11.) Check for corrosion
8.04 LIEBHERR 1141

B105034
1142 LIEBHERR 8.04

10 Appendix 2
Typical example for an inspection log
8.04 LIEBHERR 1143

B194071
1144 LIEBHERR 8.04

11 Appendix 3
Note
Depiction of deformation
The deformation that is depicted on many pictures is exaggerated in order to show it more clearly.
The ropes that are shown would have had to be taken down long before they reached this stage.
Typical examples of damage that can occur to wire ropes:

– Picture 1:
Corkscrew-like deformation: deformation where rope is in the form of a spiral along its longitudinal
axis.
The rope must be taken down if the deformation exceeds the value that is mentioned in
chapter “Take-down criteria”, section entitled “Corkscrew-like deformation”.
– Picture 2:
Basket formation on a multi-strand rope.
Reason for immediate rope take-down.
– Picture 3:
Steel core rope exit, generally in combination with basket formation in the immediate vicinity.
– Picture 4:
Only one strand is affected by loop formation, although the examination of a longer section of rope
shows that the deformation is visible at regular intervals; normally deformation along the length of
a lay.
– Picture 5:
Serious worsening of the previous problem (see picture 4) (typical of hoist rope in a ram system).
– Picture 6:
A serious reverse bend or knot.
Note the destroyed lay that leads to the exit of the fibre layer.
– Picture 7:
A wire rope that has been kinked during installation but still taken into operation, and now suffers
from localised wear and substandard rope tension.
Reason for rope take-down.
– Picture 8:
Crushing as a result of local mechanical damage causing imbalance beneath the strands,
resulting in wire breaks.
– Picture 9:
Crushing of a multi-strand rope caused by incorrect spooling up on the rope drum.
Note increase in length of outer strands of lay. Here too, imbalance would occur under load.
– Picture 10:
Example of serious kinking.
12 Appendix 4
Guideline for number of wire breaks in accordance with ISO 4309
for power train classification groups M1, M2, M3 and M4
8.04 LIEBHERR 1145

12.1 Wire ropes
12.1.1 Hoist ropes
Rope diameter Number of visible broken wires requiring rope removal,

over a length of
6 x rope diameter 30 x rope diameter
See chapter 1.03 2 4
Note
If a rotation resistant hoist rope is placed on winch 5, then it can be used for the jib adjustment or
as a hoist rope for the boom nose!
WARNING
Use the hoist rope as control rope!
Frequent jib adjustment movements with a rotation resistant hoist rope lead to significant wear and
require premature take down of the hoist rope!
If is is not recognized in time that the rope needs to be taken down, the hoist rope can rip!
The crane can topple over and personnel can be severely injured or killed!
In case of frequent jib adjustment movements, a non-rotation free control rope must be placed!
Make sure that no spin stabiliser / swivels are used as rope end connections when using a
non-rotation free control rope!
Remove spin stabiliser or swivels!
12.1.2 Assembly ropes

over a length of
12.1.3 Guy ropes, control ropes

over a length of
1146 LIEBHERR 8.04

WARNING
Non-rotation free control ropes can rip off!
If a non-rotation free control rope is used in connection with a rotating rope end connection, the rope
damage can occur or the control rope can rip off!
The crane can topple over and personnel can be severely injured or killed!
Make sure that no spin stabiliser / swivels are used as rope end connections when using a
non-rotation free control rope!
Remove spin stabiliser or swivels!
8.04 LIEBHERR 1147

026229-02 8.07 Inspection of pneumatic brake system for disk brakes
B103653
1148 LIEBHERR 8.07

8.07 Inspection of pneumatic brake system for disk brakes 026229-02
1 General
DANGER
Danger of fatal injury due to erroneous maintenance or repair on the wheel brake!
Incorrect maintenance or repair of the wheel brake can cause serious traffic accidents and
subsequent death.
All wheel brake maintenance and repair work may only be carried out by authorized and trained
expert personnel!
Use only original Liebherr spare parts!
After completion of work on the brake system, carry out a brake function test on all wheels! If
possible, we recommend a function test on the brake test bench.
The air disk brake systems on mobile cranes must be inspected annually.
In Germany, the main inspection and safety tests must be conducted in accordance with § 29 of
STVZO.
The corresponding national regulations apply for other countries.
2 Visual inspection
Check that the following requirements are met:
– Pipe and hose lines are not damaged, not corroded and are properly routed
– Devices are properly installed and fastened
– The air pressure tank is not damaged and no external corrosion is visible
The tank is labeled as specified.
No welding nor heat treatments be conducted on the tank walls.
– Water has been removed from the air pressure tank
– Dust seals are not damaged
– The wheel brakes are properly adjusted (vent clearance, brake cylinder stroke, lining thickness)
DANGER
Danger of accidents due to overheating wheel brake!
If the lower breather bore 1 is closed, the wheel brake can run hot!
The lower breather bore 1 may never the closed!
3 Function and performance test

3.1 Function test
– Pressure regulator, air cylinder: Check turn on pressure, shut off pressure and delivery rate
– Pressurized air system: Check for leaks and supply pressure
– Multi-circuit safety valve, overflow valves and warning device: Check function
8.07 LIEBHERR 1149

3.2 Performance test

Note
The following values are valid for an axle load of 12 t.
Check the function of the wheel brake:

– Press down the brake pedal: Both brake shoes contact the brake disk
– Release the brake pedal: Brake shoes immediately return to their starting position
Check effectiveness of wheel brake:
1.) Measure delay
2.) Measure brake path
3.) Determine brake performance on brake test bench
3.2.1 Determine delay with a decelerometer

At an applied pressure of 6.5 bar, the measured average delay dm should be larger than 4.5 m/s2 .
3.2.2 Measure brake path

At an applied pressure of 6.5 bar, the brake path s should be smaller than the value given in the chart.
Test speed Brake path

v s
20 km/h 6.5 m
30 km/h 12.5 m
40 km/h 19.8 m
50 km/h 29 m
3.2.3 Measuring the braking performance on the brake test bench

When the brake forces are measured on the vehicle axles, determine the brake performance as
follows:
Gz = allowable total vehicle weight [N]

z = brake performance [%]
F1 = brake force of the first axle, which was determined at pressure p1 [N]
F2 = brake force of the second axle, which was determined at pressure p2 [N]
Fn = brake force of last axle, which was determined at pressure pn [N]
pN1...n = max. brake pressure of corresponding axle [bar]
p1...n = brake pressure, which is actually applied into the wheel cylinder at the corresponding axle [bar]
during the brake test
1150 LIEBHERR 8.07

4 Internal inspection of the wheel brake

Note
Check the brake pads and the brake disks in regular intervals, depending on the vehicle use, during
maintenance interval as well as within the framework of lawful regulations.
Check the condition of the brake pads every 4 months.
Check the condition of the brake disks every 12 months.
At least every 24 months, replace the retaining springs as well as seal rings, caps and convoluted
rubber gaiters.
4.1 Checking the brake pads

DANGER
Worn brake pads or brake disks can lead to a reduction of the brake force or failure of the wheel
brake. This can result in accidents with fatal injuries.
Observe the wear limits of the brake pads and the brake disks!
Replace worn brake pads or brake disks!
Replace the wheel brake if significantly damaged or if the castings are worn (for example, if they
show cracks)!
Change burnt, slick or oily brake pads as quickly as possible!
Always replace all the brake pads on each axle!
The brake pads are electrically monitored and can also be optically checked on the brake pads.
4.1.1 Checking the brake pads electrically
If the warning light 204 on the display unit lights up, it is a sign that at least one brake pad on the
crane is worn and has reached the wear limit.
To find the worn brake pad, see chapter 20.20.
DANGER
Danger of fatal injury in case of worn brake pads!
As soon as the warning light 204 lights up, the worn brake pads must be localized and replaced. If this
is not done, the wheel brake can fail, which can cause fatal accidents, or the brake disks can be
damaged.
Replace worn brake pads!
4.1.2 Checking the brake pads optically
8.07 LIEBHERR 1151

DANGER
Danger of fatal injury in case of worn brake pads!
Replace brake pads no later than when the weakest point measures 2 mm of brake pad thickness
over the brake pad carrier plate. The remaining pad thickness may not fall below 2 mm. If this is not
done, the wheel brake can fail, which can cause fatal accidents, or the brake disks can be damaged.
Replace worn brake pads!
If the remaining pad thickness A is less than 2 mm it is imperative that the brake pads are
replaced.
1 = Pad carrier plate

2 = Brake pad
Component Dimension
A Remaining pad thickness 2 mm
B Total pad thickness 23 mm
4.2 Checking the brake disks
4.2.1 Checking brake disk wear
DANGER
Worn brake pads or brake disks can lead to a reduction of the brake force or failure of the wheel
brake. This can result in accidents with fatal injuries.
Replace worn brake pads or brake disks!
If the brake disk reaches the wear limit of D = 33 mm, then it must be changed immediately!
If the brake pad and the brake pad carrier plate reaches the minimum thickness of H = 11 mm,
then the brake pad must be changed immediately!
We recommend to change all the brake disks on each axle.
Generally, after installing the new brake disks, we recommend to use new brake pads also.
1152 LIEBHERR 8.07

Remove the brake pads and measure the brake disk thickness in the contact area of the brake pads.
Component Dimension
C Total thickness of new brake disk 41 mm
D Wear dimension limit brake disk 33 mm
E Total thickness of new brake pad 32 mm
F Brake pad carrier plate 9 mm
G Minimum thickness of brake pad 2 mm
H Absolute minimum thickness brake pad and 11 mm
brake pad carrier plate
4.2.2 Checking brake disk condition

Check brake disks for cracks and surface condition as well as for maximum wear dimension.
a = Brake surface
8.07 LIEBHERR 1153

Irregularity Evaluation
A Net-like crack formation permissible
B Cracks running to hub center to maximum 0.5 permissible
mm width
C Irregularities of disk surface below 1.5 mm permissible
D Continuous cracks impermissible
4.2.3 Checking brake disk impact
DANGER
Risk of accident!
If the brake disk impact exceeds the limit value of 0.15 mm, then the brake disk must be changed
immediately!
– Attach the test gauge on the wheel brake carrier.

– With installed brake disk, check the brake disk impact by turning the wheel hub, see illustration.
1154 LIEBHERR 8.07

9.00 General notes
LIEBHERR 1155
027300-04 9.02 Supplementary service work
B195219
1156 LIEBHERR 9.02

9.02 Supplementary service work 027300-04
1 Checks before start up

We recommend to carry out the following visual inspections in the engine compartment before start
up:
– Check if all oil and fuel lines are leak-free and dry.
– Check if the injection pump, fuel and oil filters are leak-free.
– Check if the hydraulic units, the hydraulic motors for the fan drives and their supply lines are
leak-free.
– Check if the exhaust system and exhaust flange are leak-free.
– Check if the exhaust flap retention flap is moveable.
The return springs that open the exhaust flaps must function properly, because seized (therefore
closed) exhaust flaps during engine operation will result in considerable overheating.
– Inspect electrical wiring and ensure that there is sufficient clearance to hot exhaust system piping
and that it is properly fastened and that there is no insulation damage.
– Inspect the soundproofing mats for soiling from solutions and large quantities of oil or fuel, as well
as other damage.
Immediately remove any soundproofing mats that are excessively damaged or soiled and replace
them with original parts.
When cleaning the engine and gear compartments, observe the care instructions for the sound
insulation, see Crane operating instructions, chapter 7.01!
2 Repair and maintenance tasks

Note
Repair and maintenance tasks are to be carried out carefully!
Take particular precautions regarding cleanliness when replacing diesel and oil filters. Remove any
diesel fuel or oil that has leaked. Perform a test run on the systems to ensure that there are no leaks.
The diesel engine V-room must be inspected regularly, and any oil or diesel fuel must be cleaned up,
particularly after repairs and servicing. Any fuel that has collected in V-room can spread throughout
the engine room while the crane is travelling on the road and can ignite if it comes into contact with
hot surfaces.
We stress that all electrical wiring must be installed according to the regulations and must be properly
fastened. Immediately repair any wiring insulation that exhibits signs of chafing or brittleness as a
result of operational activities. Any wiring that is not in perfect condition is to be immediately and
professionally replaced.
We would like to particularly emphasize that over time fuel and oil lines can become brittle or porous
as they age. Any hoses that appear to be excessively porous should be replaced immediately, see
crane maintenance chapter.
3 Important service tasks

The following service tasks are to be carried out regularly:
– Grease drive shafts with LIEBHERR special grease.
– Regularly check that the drive shaft bolts are properly seated.
– Check gearbox and engine oil levels regularly.
Replace any oil used in normal operation. If oil consumption or loss is unusually high, determine
the cause and correct.
9.02 LIEBHERR 1157

4 Maintenance notes for replacement parts

The following is to be considered when replacing drive components such as engine, gearbox or axles:
– Before start up, be sure to refill with the correct type of oil to the center of the min. - max. marks.
For type of oil, refer to the data tag and service items and lubricants.
– Conduct initial maintenance according to chapter “Maintenance intervals”; thereafter, maintain in
accordance with the specified periodic maintenance intervals.
– Observe break-in instructions, see chapter 2.02.
5 Recommendations for travel operation

NOTICE
Risk of engine damage!
If the permissible engine speed in exceeded, the engine can be seriously damaged!
Do not exceed the permissible engine rpm!
6 Disposal of fuels and lubricants

Note
Engine, gearbox and hydraulic oils, brake fluids, grease and fuels are dangerous waste materials!
These materials must be disposed of separately!
These materials may not be disposed of in the ground or in any bodies of waters: wastewater
systems, sewers or groundwater!
Comply with the regulations specified by local authorities before disposing of any of these items or
substances!
Note
Radiator fluid for diesel motors and heating systems are dangerous waste materials!
Undiluted antifreeze / anti-corrosion agents must be handled as dangerous waste materials!
Follow the regulations of the local authorities when disposing of used cooling fluids (mixture of
antifreeze / anti-corrosion agents solution and tap water).
7 Tires
For EM-tires (Earthmover tires) there is no legal specification for tire replacement due to tire aging
either from the tire manufacturer or by law. The tires must be replaced when the legally specified
minimum tire tread depth is reached.
To ensure that the tires on the crane vehicle obtain a long service life, we recommend to proceed as
follows:
Observe the axle loads specified by law!
Keep the respective travel conditions specified by LIEBHERR-Werk Ehingen GmbH!
Check in regular intervals:
• The tire pressure
• The tire tread depth
• The tire surface for cracks, damage or foreign particles
• The tire outer wall for cracks to damage
• The track adjustment for all axles
1158 LIEBHERR 9.02

Note
These inspections cannot ensure that the EM-tires do not have internal, non-visible damage and
that the EM-tire cannot be used further.
The crane operator must monitor the externally recognizable condition and any changes of dynamic
behavior, such as increasing noise or vibrations. If any of these features decrease, that could be a
sign that the tire must be taken out of service.
Note
We recommend after 8 to 10 years, even if the EM-tire does not show any external damage, to
have the tires check by an authorized expert personnel of the respective tire manufacturer and to
observe the recommendations regarding continued use of the tire.
7.1 Wheel checks
DANGER
If the lock ring 2 is not properly seated in the groove, it can be violently ejected when the tire is inflated
and fatally injure personnel!
If the lock ring 2 is not correctly seated in the groove, please obtain the assistance of an
authorized and trained expert personnel!
Do not make any alteration to the tire pressure!
Visually check the side ring and lock ring 2 for correct seating!
DANGER
In the event of insufficient profile or damage to the tires, exchange tires for new ones!
Maintain correct tire pressure! See chapter 1.03.
If the tire pressure has dropped below 3 bar, the tire may only be pumped up by qualified and
trained personnel!
Replace damaged disk wheels 1 with new ones immediately!
Check depth of tread.

Check tires for damage.
Check the tire pressure.
Check wheel disks 1 for damage.
9.02 LIEBHERR 1159

7.2 Tire changes

WARNING
Mortal danger when using non-approved tires and disk wheels!
By using tires and disk wheels which are not explicitly approved by LIEBHERR-Werk Ehingen
GmbH, unforeseeable, dangerous operating conditions can occur!
The tires and the disk wheels can be destroyed and the mobile crane and the environment can be
severely damaged!
Use only spare tires and disk wheels which have been approved in writing by LIEBHERR-Werk
Ehingen GmbH!
Using spare tires and disk wheels which have been not explicitly approved in writing by
LIEBHERR-Werk Ehingen GmbH is prohibited!
Note
Tires may only be changed by authorized and trained specialist personnel!
This applies both to dismounting and mounting of the tire on the disk wheel 1!
7.3 Wheel changes
7.3.1 In event of tire failure
Note
The following is to be considered in the event of tire failure!
Pay attention to road traffic when stopping!
The steering wheel could judder. Hold on to the steering wheel tightly with both hands!
Select the flattest possible surface for undertaking a wheel change! Select the site in such a way
that the road traffic is obstructed as little as possible and you will not be endangered when
changing the wheel!
Secure the vehicle and the breakdown site!
“Free-standing” crane operation is absolutely prohibited!
WARNING
Toppling wheel!
The wheel can topple over when changing the wheel and seriously injure personnel!
Secure the wheel against toppling!
Only operate the support when no wheels are leaned against a sliding beam or support cylinder!
Step away quickly if a wheel threatens to topple!
Change the wheel with the help of a second person if possible!
Apply the parking brake, see chapter 3.04.

Lock the axle suspension, see chapter 3.03.
Loosen wheel lugs on the defective wheel.
DANGER
Select a support base where the mobile crane cannot topple over!
Support the mobile crane until the wheels can be changed, see chapter 3.05.
1160 LIEBHERR 9.02

Wheels that are on their side are extremely difficult to lift up. For this reason, do not place wheels
down when changing a wheel.
Lift the spare wheel using the crane, set it down next to defective wheel and prevent it from rolling
away or toppling over.
Unscrew wheel lugs and remove defective wheel.
DANGER
Defective spare wheel!
Before mounting, visually inspect the disk wheel 1, the side ring, the clamp collar 2 and the tire!
Never mount a defective spare wheel!
Only mount wheels that are approved for the vehicle!
Mount the spare wheel.
WARNING
Risk of accident if wheel lugs are overtightened!
The tightening torque is 600 Nm!
Do not overtighten wheel lugs!
Only use wheel lugs approved by LIEBHERR-Werk Ehingen!
Reinstall the wheel lugs and tighten them crossways with 600 Nm.
After the first 50 and the first 100 travelled kilometres:
Ensure that wheel lugs are tight, re-tighten if necessary.
7.3.2 Rotating the wheels

Crane vehicle tires are subjected to differing loads during operation.
Tire rotation is recommended to ensure that all the vehicle's tires wear uniformly. Tires should be
rotated as soon as uneven wear patterns are detected. We recommend intervals in the range of
5000 km and 10000 km. Tires should be rotated in a crosswise pattern (see following illustrations).
The location should also be selected so that tires that are evenly worn are installed in locations where
the wear pattern is uneven.
This process has a positive impact on driving comfort and tire performance.
9.02 LIEBHERR 1161

B108267
1162 LIEBHERR 9.02

B108268
9.02 LIEBHERR 1163

B108269
1164 LIEBHERR 9.02

B108270
9.02 LIEBHERR 1165

1166 LIEBHERR
90.00 Appendix
LIEBHERR 1167
028514-00 90.01 Foreword to appendix
1168 LIEBHERR 90.01

90.01 Foreword to appendix 028514-00
blank page!
90.01 LIEBHERR 1169

028514-00 90.01 Foreword to appendix
B195219
1170 LIEBHERR 90.01

90.01 Foreword to appendix 028514-00
1 Preface
This crane may only be used in flawless technical condition and according to its mission as well as
with constant awareness of safety and dangers. Any problems, which could affect safety must be
fixed immediately.
Note
Modifications on the crane may only be made with written approval by Liebherr-Werk Ehingen
GmbH.
1.1 Changes and updates for Operating instructions

Changes and updates for Operating instructions, which you receive in the circular as Customer
information, must be filed in the Operating instructions for the respective crane under chapter 90.05.
Note
Procedure after receiving customer information!
File changes and updates in the Operating instructions under chapter 90.05 and fill our the update
confirmation.
Attach the decals 1, which are enclosed in the customer information to the footer of the respective
chapter. See following example.
Example:
A change or update affects the Crane operating instructions, chapter 2.04 on page 108.
Attach the decal 1 in the footer of chapter 2.04 on page 108.
90.01 LIEBHERR 1171

028515-00 90.05 Update confirmation
B195219
1172 LIEBHERR 90.05

90.05 Update confirmation 028515-00
1 Update confirmation
Date Change / update Completed

on by
90.05 LIEBHERR 1173

1174 LIEBHERR
Index
Assembly 519, 773, 777, 833
1 Assembly / disassembly 649
10 x 8 drive 27 Assembly / disassembly of booms 651
Assembly of lattice sections for lattice mast
cranes 665
A Assembly of lattice sections for telescopic
Aborting telescoping 487 cranes 653
Access into the automatic lubrication (intermediate Assembly of the auxiliary boom carried on the
lubr 965 crane 791
Active stand-by operation / alarm 415 Assembly of the double folding jib carried on the
Air conditioning system* operation 857, 869 crane 699
Air filter 919, 953 Assembly of the single folding jib carried on the
Air dryer of the compressed air system of the crane crane 693
superstructure 979 Assembly process 833
Additional boom 23 Attaching / removing the hoist limit switch
Additional equipment 841 weight 505
Additional equipment 27 Attaching the hoist limit switch weight 505
Addition of longitudinal differential lock axle 4 + Attaching the load 533
tran 237 Attachment points on folding jib / folding jib
Addition of longitudinal differential lock in transfer extension 123
g 235 Attachment points on folding jib 121
Addition of transversal differential lock axle 1 (with Attachment points Telescopic boom extension 831
1 237 Automatic gear box 203
Adjusting crane operator's seat 421 Automatic transmission 923
Adjusting the folding jib angle of the hydraulic Auxiliary boom 786
folding jib 737 Axle casings 943
Adjusting the mirrors 169 Axle loads 30
Adjusting the driver's seat 167 Axle loads more than 12 t 183
Adjusting the steering wheel 169 Axle loads up to 12 t 183
Alarm functions 335 Axle locking system 181
All wheel steering 247 Axles 943
Angle assembly with hoist rope as holding Axles 25
cable 719 Axles locked 173
Angle display for folding jib 737 Axles sprung 173
Angular assembly with supported folding jib 721 Axle suspension system 172
Angular pull 535 Axle suspension system 175
Antifall guards on the crane 117
Antifall guards on the crane 119 B
Appendix 1 1141 Ball valve positions during emergency
Appendix 2 1143 operations 879
Appendix 3 1145 Battery maintenance 947
Appendix 4 1145 Beaufort Wind chart 95
Appendix 1167 Before leaving the work site 283
Appendix 1116 Bleeding the central lubrication system 967
Applying the slewing gear brake 475 Block position of relapse cylinders when setting
Assemble winch2 773 down a 642
Assembling / disassembling the wedge lock 509 Bluetooth™ Terminal (BTT) 1011
Assembling / disassembly of hydraulic lines 677 Boom nose 776
Assembling the 3-piece folding jib 703 Boom nose* 45
Assembling the 4-piece folding jib 707 Brakes 26
Assembling the auxiliary equipment* 547 Breaking away fixed loads 537
Assembling the folding jib 691 Breaking in the brake linings 47
Assembling the hose couplings in operating or Break-in instructions 46
neutral po 723 Break-in instructions 47
Assembling the separately transported auxiliary Bypassing during crawler assembly 677
boom 795 Bypass of shut off luffing the telescopic boom /
Assembling the separately transported folding jib on attachm 597, 633
the 711 Bypass of the hoist top shut off 593, 629
LIEBHERR 1175
Index
Checks before starting up 417

C Checks before start up 1157
Calculating the minimum required hook block Checks to be performed 283
weight 815 Check the relapse cylinders for visible defects 1111
Calculation examples 818 Cleaning and care of the crane 890
Can the support cylinders or sliding beams no Command and prohibition signs 109
longer be 883 Command sign 109
Care instructions for the cab and the crane Component overview 787
operator's c 891 Components of the system 963
Carry out error diagnostics 1019 Compressed air and brake system air dryer 941
Catch bar 451 Create hydraulic connection 835
Central lubricating system, troubleshooting 969 Creeper gear (off-road gear / manoeuvring
Central lubrication system 963 mode) 215
Change over with supported folding jib 745 Condition before installing 1127
Change over with the hoist rope as holding Condition of equipment that is functionally asso-
cable 743 ciated with the rope 1133
Changes and updates for Operating Connect supply lines 773
instructions 1171 Consideration of wind conditions 96
Changing between operating modes 247 Control elements Roof console 289
Changing maximum luffing speed 385 Control measures - crawler cranes 642
Changing mechanical folding jib from 0° to 22.5° or Control measures - mobile cranes 641
45° 717 Control of crane movement 477
Changing the fine filter 925 Cycle control 965
Changing the low idle speed 195 Control release 451
Changing the maximum rotation speed of slewing Controls 26
gear 383 Convert from driving mode to crane operation 253
Changing the mechanical folding jib from 22.5° or Converting from crane operation to driving
45° to 0° 741 mode 257
Changing the oil 929, 955, 977 Coolant Engine cooling 919, 953
Changing the wheel 941 Cornering and shunting 135
Chassis operating instructions (position 16) 113 Counterweight combinations 513
Checking central lubrication system 417 Counterweight 512
Checking general condition of crane 419 Counterweight 27, 83
Checking oil level and filters 417 Coupling and decoupling the dolly to/from the
Checking the antislip coverings 890 crane 129
Checking the battery voltage 890 Crab steering 248
Checking the brake disks 1152 Crane alignment 82
Checking the brake pads 1151 Crane at the job site 252
Checking the coolant level 161, 417 Crane chassis 25
Checking the counterweight plates 515 Crane Chassis 21
Checking the fuel level 161, 417 Crane chassis maintenance and inspection sched-
Checking the gas pressure and oil fill 1111 ule 897
Checking the general transport condition 163 Crane chassis operation 139
Checking the important operating instruments 171 Crane Components 21
Checking the instruments after starting the Crane engine 951
engine 191, 435 Crane engine 26
Checking the lights 165 Crane geometry and load information 329
Checking the oil level and filters 161 Crane movement - Telescoping 531
Checking the oil level 927, 955, 977 Crane operation 454
Checking the oil level on the automatic Crane operation 537
transmission 923 Crane operation 85
Checking the prerequisites 679 Crane operation in case of thunderstorms 88
Checking the retaining elements 639 Crane operation with a load 83
Checking the ropes 639 Crane operation with auxiliary block* 511
Checking the safety measures 82 Crane operation with auxiliary block* on the tele-
Checking the signal horn 427 scopic boom 511
Checking the tires 161, 941 Crane operator's cab with incline adjustment 53
Checking the wheel alignment 945 Crane operator's cab with retractable / extendable
Checks before starting to work with the crane 530 step 53
1176 LIEBHERR
Index
Crane operator's cab workplace 421 Driving speeds with 445/95 R 25 and 525/80 R 25
Crane drive 26 tires 32
Crane driver's cab 27 Driving with counterweight plates placed on vehicle
Crane driving conditions 183 fram 527
Crane speeds 32 Driving with the equipment in place 181
Crane start up and taking the crane out of Dual hook operation 781
service 416 Danger of being crushed! 537
Crane superstructure 26 Danger of burns (position 29) 104
Crane superstructure 21 Dangerous conditions without shut off 642
Crane superstructure maintenance and inspection
schedule 907
Cranes with luffing* cab 127
Create electrical connection 835
E
Electrical connections on the double folding jib 731
Create electrical/hydraulic connections 835
Electrical connections on the single folding jib 729
Electrical system 26, 27
“ Electrical system - lighting 947
“Configuration” program areas 311 Electrical system - Lighting 979
“Configuration” program 309 Emergency exit - crane operator's cab 55
“Control parameter” program 379 Emergency exit 55
“Power Plus” rapid gear 459 Emergency exit - driver's cab 55
“Telescoping” program 375 EMERGENCY OFF switch* 451
“Winch display” icon 361 Emergency operation 879
Emergency operation of support 882
Emergency operation of support 883
D Emergency operation with the drive motor 881
Danger zone of crane 51 Emergency take-down 878
Description 173 Endangering air traffic 89
Description of crane 19 Engine monitoring 435
Determining the factor for reeving 816 Engine monitoring icons 411
Determining the rope weight for the rope Engine oil 917, 951
diameter 816 Engine rpm 457
Diaphragm reservoir 959 Ending crane operation 99
Diaphragm reservoirs of axle suspension / axle Ending crane operation 99
blocking 935 Ending driving 233
Diesel engine 917 Equipment 637
Diesel particle filter* 919, 953 Erection and take-down charts 838
Differential locks 235 Erection 735, 803
Dimensions 29 Erection procedure 735, 803
Dimensions support base 29 Erection / take down for crawler cranes 679
Dimensions support pad 29 Erection / take down for mobile cranes 678
Disassembling the wedge lock 509 Erection / take down 678
Disassembly of the counterweight plates 523 Error diagnostics without the help of Liebherr
Disconnecting the supply lines 775 Service 1019
Dismantling 775, 783, 837 Error diagnostics with the help of Liebherr
Dismantling process 837 Service 1019
Dismantling the auxiliary boom carried on the Establishing the hydraulic connections 723
crane 809 Exceeding the overload protection 647
Dismantling the auxiliary boom 807 Exceeding the shut off limits of the LICCON
Dismantling the winch2 775 overload pro 599, 635
Displays in “Operation” program 387 Exhaust systems and other heated crane compo-
Display unit 151 nents 51
Disposal of fuels and lubricants 1158 Extended manoeuvring coupling* 251
Does the touch display remain dark? 1017 Extending sliding beams from the crane cab 275
Dolly 137 Extending support cylinders from the crane cab 277
Driver cab 26 Extending support cylinders with support control
Drive with a total weight of 75 t 185 unit 263
Driving 195 Extending the sliding beams with support control
Driving on inclines and slopes 133 unit 261
Driving speeds with 385/95 R 25 tires 31 Earthing the mobile crane 159
LIEBHERR 1177
Index
Electrical connections 729 General 57, 62, 181, 241, 259, 273, 479, 519, 523,
Electrical connections on auxiliary boom 799 537, 691, 749, 787, 807, 879, 1137
F H
Have the hydraulic, electric or engine failed? 1009
Fastening points on the crane superstructure 127
Heater / engine pre-heating 842
Fastening points on the telescopic boom 119
Heater operation 843, 859
Fastening points “separated folding jib” 689
Heating the crane operator's cab 859
Fastening the seat belt 169
Heating the driver's cab 843
Filling the grease container 965
Height of vehicle 131
Filling the lubrication lines 967
Hoist gear 2 772
Fill quantities for crane chassis 983
Hoist gear 26, 973
Fill quantities for crane superstructure and
Hoist gear, hoist rope 84
boom 985
Hoist gears 973
Fill quantities 983
Hoisting heights 32
Fill quantities, lubrication chart 982
Hoisting limit switch 781
Fold boom nose into operating position, Fig. 3 and
Hoist limit switch “Hoist top” 447
4 779
Hook block overview 821
Fold boom nose to transporting position, Fig. 5 and
Hook blocks 814
6 783
Hydraulic adjustable folding jib with extension
Folding jib 27
(TNZK)* 23
Folding jib - TK 680
Hydraulic adjustable folding jib with extension
Folding jib, type TK* 23
(TVNZK)* 23
Folding jib versions 681
Hydraulic connections 723
Folding jib with extension (TVK)* 23
Hydraulic cylinder 891
Footboard 423
Hydraulic hose lines 935, 960
For cranes with pneumatic boom locking
Hydraulic oil reservoir 931
system 1111
Hydraulic oil tank 957
For cranes with telescopic boom system
Hydraulic safety valves 451
Telematik 1111
Hydraulic system 931, 957
Foreword to appendix 1168
Hanging the counterweight plates as a package 517
Frame 25, 26
Handling of hook blocks 821
Fuel pre-filter 921
Hand signals for guidance 95
Function and performance test 1149
Function check 733, 781, 963
Function key line 411 I
Function test 1149 In addition, the following applies for Germany: 87
Fastening point 787 Independent steering 248
Fastening points “folding jib complete” 685 Index 1175
Fastening points 119 In-line filter in crane hydraulics 959
Inspecting load hooks 1109
Inspecting the cable pulleys 1112
G Inspecting the function of the overload
Generally valid instructions: 86 protection 1112
General notes 1155 Inspecting the hoist and luffing winches 1097
General operating elements 287 Inspecting the mounting of the load bearing
General operating instruments 141 equipment 1112
General safety technical guidelines 50 Inspecting the oil and fuel reservoirs 1115
General safety technical notes for driving with Inspecting the roller ring connection 1112
dolly 128 Inspecting the rope feed mechanics in the tele-
General towing regulations 251 scopic boom 1109
Grounding 87 Inspection according to ISO 4309 1128
Grounding the crane 87 Inspection and monitoring procedure 1109
Grounding the load 88 Inspection of carrying crane structures, especially
Guiding the load 537 steel structures 1030
Guy rods 644 Inspection of change over pulleys, illustration
General checks before starting to drive 161 2 1115
General 51, 173, 253, 301, 443, 455, 513, 541, 561, Inspection of crane wire ropes 1126
681, 773, 777, 787, 831, 839, 871, 889, 1029, 1149 Inspection of disk wheels 1096
1178 LIEBHERR
Index
Inspection of lattice sections 1093

Inspection of locking system of telescopic L
boom 1111 LICCON computer system boot up 303
Inspection of membrane accumulator 1111 LICCON computer system 300
Inspection of pneumatic brake system for disk LICCON computer system 443, 463
brakes 1148 LICCON computer system in stand-by mode 413
Inspection of relapse cylinders 1111 LICCON monitor 1013
Inspection of the auxiliary reeving winch, towing Liebherr Customer Service is for you 889
winch and spare wheel winch 1115 Lifting / lowering 469
Inspection of the safety controls on the relapse Lifting / lowering winch 1 469
cylinders 1112 Lifting / lowering winch 2 469
Inspection of the tele extension with eccentric, Lifting of personnel 86
illustration 1 1115 Lifting the individual counterweight plates from the
Inspection of tire pressure 1095 veh 527
Inspection of tires and disk wheels 1095 Lifting the load 535
Inspection of tires 1095 Limit switch winch spooled out 447, 449
Inspection procedures 640 Load tackle 30
Inspection recommendations for periodic inspec- Lowering the hook block if slack rope forms 818
tions of 1116 Lubricate the rotary connection 971
Inspections 1097 Lubricating the gear ring and the slewing gear
Inspections of cranes 1027 pinion 971
Installation 1127 Lubricating the telescopic boom 981
Installing the auxiliary boom 787 Lubrication schedule - Crane chassis 987
Installing the auxiliary weights 823 Lubrication schedule - Crane superstructure and
Installing the hook device on the ladder 121 boom 989
Installing the hydraulic hose drum 727 Lubrication schedule - Equipment 991
Installing the single blocks 823 Lubrication schedule 987
Installing the wedge lock 509 Luffing 465
Instructions for resuming crane movements for Luffing gear 27
cranes with CE mark 565 Luffing lattice jib limit switch 453
Instructions for resuming crane movements for Luffing the folding jib* 467
cranes without CE mark 601 Luffing the telescopic boom 465
Instructions for sound damping (soundproofing) 890 Luffing with “hydraulic angle adjustment” 737
Internal inspection of the wheel brake 1151 Level control 175
Interruption of crane operation 98 Levelling instruments 443
Interruption of crane operation 98 LICCON computer system after engine start 439
Introduction 1127
Is a limit switch defective? 1025
Is a sensor defective? 1023
M
Maintenance 57, 1127
Is telescoping not possible? 1017
Maintenance guidelines - Crane chassis 916
Is the central processing unit defective? 1021
Maintenance guidelines - Crane superstructure 950
Is the electrical connection of a cable drum
Maintenance intervals - Crane chassis 895
interrupted 1023
Maintenance notes for replacement parts 1158
Is the LICCON monitor defective? 1021
Maintenance work on the crane superstructure or
Is the power supply defective? 1021
boom 891
Important check before swinging out the hydraulic
Manual rope winches for assembly support of
foldin 693
components 643
Important indicator instruments while driving 221
Measures before tilting 947
Important service tasks 1157
Measures for defective components 1021
Measures in clear problem cases 1007
Measures taken upon work interruption or
J transport 891
Job planning 48 Mechanically actuating the hoist limit switch,
Joint lifting of a load by several cranes 90 illustrat 729
Mechanical relapse retainer on the luffing lattice
jib 453
Method of operation of sliding beam monitoring 877
K Minimum required hook block weight 815
Keyboard 147 Mixing battery acid 948
LIEBHERR 1179
Index
Monitored auxiliary functions for crane boom 541

operation 349 Operation with auxiliary pulley block on pivot
Motor 25 section* 547
Move boom nose to operation position, Fig. 1 and Other operating elements 369
2 777 Overload protection 444
Movement on the crane 51 Overload protection (LMB) 301
Moving and securing the support pads to transport Overview load chart for cranes with CE mark 565
positi 267, 279 Overview load chart for cranes without CE
Moving the railing into position for assembly / mark 601
disassem 125 Overview of acoustic / visual warnings for cranes
Moving the railing into transport position 125 with C 567
Moving the support pads from operating position Overview of acoustic / visual warnings for cranes
(illustr 255 withou 603
Moving the support pads from transport position Overview of displays and component groups for
(illustr 255 error diag 1005
Maintanance intervals - Crane superstructure 905 Obligations of the crane operator 68
Maintenance and inspection guidelines 892 On road driving 247
Maintenance and service - General 888 Opening front window 427
N P
Notice sign for data logger 115 Periodic crane inspections 1028
Notice sign for refueling (position 49) 114 Permissible ground pressures 76
Notice sign for vehicle height (position 19) 113 Permitted ground pressure for crawler cranes 77
Notice signs 113 Permitted ground pressure for mobile cranes 77
National traffic regulations 45 Personal protective equipment 65
Non-rotation free ropes and their rope end connec- Picking the counterweight plates up 521
tions 1134 Placing the hoist rope 639
Note for speed limiter (position 50) 115 Planning crane operation 49
Pneumatic springs for assembly support of compo-
nents 643
O Possible engine monitoring advance warning, warn-
Operating and control instruments 287 ing and 407
Operating and monitoring instruments on the crane Parking brake 197
chassis 140 Preface 1171
Operating and monitoring instruments on the crane Preparatory work before swivelling in hydraulic
superstructure 286 folding 751
Operating behavior of steel ropes 1133 Preparatory work 735, 803
Operating elements of the LICCON computer Preparing the crane 873
system 307 Preparing the hook block for crane operation 825
Operating elements on camera-monitor* 145 Preparing the hook block for removal 827
Operating elements on control console (machines Pressure filter in the crane hydraulic 959
with one 293 Procedure for shut off of crane movements 560
Operating elements on the control console (cranes Procedure in case of problems 1002
with t 297 Procedure in case of slack rope 818
Operating engine-independent auxiliary heating for Procedure to follow in case of an error 877
engin 853, 865 Procedure to follow in case of a problem 1003
Operating engine-independent auxiliary Procedure to follow in case of a problem 1003
heating* 849, 861 Prohibition signs 110
Operating instructions for maneuvering mode (posi- Product description 24
tion 22 114 Pump distributor gear 955
Operating mode preselection on the LICCON Parking the vehicle 99
computer syste 305 Performance test 1150
Operating the windshield wiper / windshield wash-
ing syst 427
Operation of crane superstructure 285 R
Operations with a boom extension (folding jib, Read the operating instructions (position 35) 114
auxiliary 545 Recommendations for travel operation 1158
Operations with a boom nose* on the lattice jib 543 Reeving in the hoist rope 715
Operations with a boom nose* on the telescopic Reeving in the hoist rope 715, 797
1180 LIEBHERR
Index
Reeving in the hook block 495

Reeving in, T-operation 549 S
Reeving out the hoist rope on the telescopic boom Safety devices on the crane 447
head 693, 788 Safety 43
Reeving plans 546 Safety guidelines for ladders 57
Reeving plans 547 Safety instructions for external power supply (230 V
Reeving procedure 491 AC) 88
Reeving the hoisting cable 781 Safety signs on the ladders 59
Reeving the hoist rope with the auxiliary reeving Safety systems 451
rope 491 Safety systems 443
Reeving the hook block in and out 495 Safety technical guidelines for assembly and
Reeving TK / TVK / TNZK / TVNZK operation 559 disassembly 638
Reinstalling the drive shaft after tilting the cab 947 Securing and removing the load hook* 501
Removal of 3-piece folding jib 763 Securing the load hook* 501
Removal of 4-piece folding jib 767 Selecting the location 253
Removing and recharging the battery 948 Selecting the location, illustrations 1 to 3 73
Removing the auxiliary weights 827 Selecting the new configuration and hoist rope
Removing the counterweight plates 525 reeving 441
Removing the folding jib 749 Selecting the telescoping target 481
Removing the hoist limit switch weight 507 Service and maintenance 887
Removing the hydraulic hose drum 725 Service brake 199
Removing the load hook* 503 Service fluids and lubricants 992
Removing the double folding jib carried on the Service items and lubricants (continuation) 994,
crane 757 995, 996, 997, 998, 999, 1000, 1001
Removing the separately transported auxiliary Service items and lubricants 993
boom 813 Service items and lubricants required for
Removing the separately transported folding jib 771 LIEBHERR cranes 993
Removing the single blocks 827 Setting the lubrication and break periods 963
Removing the single folding jib carried on the crane, Setting the operating mode and equipment configu-
p 753, 755 ration 309
Repair and maintenance tasks 1157 Setting the support bases 871
Repair welds 1032 Setting up 835
Replacing the granular cartridge 941, 979 Setup and takedown chart for the TK/TNZK
Replacing the oil in the automatic transmission 925 operation 839
Requirements for monitoring the winches 1098 Setup and takedown chart for the T-operation 839
Requirements of the crane operator 62 Setup and takedown chart for the TVK/TVNZK
Retaining the engine monitoring screen 409 operation 840
Retarder 199 Shut off of crane movement 577, 613
Retracting sliding beams from the crane cab 279 Shut off of crane movement: LML-STOP by
Retracting sliding beams with support control LICCON overload 583, 619
unit 269 Signs on the crane 101
Retracting support cylinders from the crane cab 279 Single hook operation 781
Retracting support cylinders with support control Slewing gear 977
unit 267 Slewing gear 27
Reduced swing-out rate 248 Slewing gear, General 473
Road driving / off-road driving 175 Slewing range (position 41) 105
Rope end connections 489 Slewing ring connection 971
Rope diameter 32 Sliding beam length display* 403
Rope inspection log 1133 Sliding beam monitoring function and error
Rope pulleys 639 display 873
Rope reeving 488 Sliding beam monitoring 870
Rope reeving 511 Slopes and excavations, illustrations 4 and 5 76
Rope storage and marking 1133 Special functions 345
Rotation-resistant ropes and their rope end connec- Speeds 31
tions 1133 Stabilizers 29
Railings on the crane superstructure 125 Stacking the counterweight plates on the
Ram work or pulling sheet piles 538 vehicle 519
Stand-by mode 463
Starting and stopping superstructure engine and
LIEBHERR 1181
Index
chassis engine 429 Take-down criteria 1130

Starting and stopping the engine 187 Telescoping to the selected target 485
Starting chassis engine 433 Telescoping with the operating screen 487
Starting chassis engine with flame starting Tempomat 227
device 433 Temposet 231
Starting LICCON computer system in stand-by Terminology 20
mode 413 The crane engine is running. 463
Starting / stopping the program 389 The “Engine monitoring” program 405
Starting superstructure engine 429 The engine does not start from the crane operator's
Starting the engine 187 cab? 1009
Starting the program 375, 379, 387, 405 The engine does not start from the driver's
Starting the superstructure engine with heat flange cab? 1007
cont 431 The function key line 365
Start prevention 415 The “Operation” program 327
Steering 241 The “Support” program 273, 389
Steering 25 The “Working range limitation” program* 387
Superstructure 455 Tilting crane cab 425
Supplementary service work 1156 Tilting the driver's cab 947
Support bases 871 Tilt play of roller ring connection 971
Support control unit 259 Tire changes 1160
Support control unit 155 Tires 30, 1158
Support force monitoring* 397 Tires 25, 27
Support forces 29 Tires / wheels 941
Supporting 81 Tires with “speed symbol E” 30
Supporting the crane 181 Tires with “speed symbol F” 30
Support pads, illustration 3 255 Towing 251
Supports 25 Towing with a defective engine and / or trans-
Suspension 25 mission 251
Swinging the rope guide pulley into operating Towing with an intact engine 251
position 715 Traffic regulations 44
Swinging the rope guide pulley into transport Traffic regulations 45
position 747 Transfer gear box 927
Switching back to the “Operation” program 385 Transmission 25
Switching on axle locking 181 Transporting components 642
Switching the slewing gear to coasting 473 Transporting lattice sections 643
Switching the sliding beam illumination on 271, 281 Travel operation 182
Swivel boom nose into transport position, Fig. 7 and Travel operation with dolly 129
8 785 Turning 471
Safety equipment 442 Turning heater / ventilation on 423
Safety equipment 27 Turning out extremely rotation-resistant hoist
ropes 1137
T Turning / driving in reverse 99
Turning the chassis engine off 437
Taking over the previously selected configuration
Turning the crane superstructure 471
and ho 439
Turning the engine off 193
Taking up crane operation again 98
Turning the heater / ventilation on 169
Taking up crane operation again 98
Turning the differential locks off 239
Technical data 28
Turning the seat heating* on 423
Technical safety instructions for working with a
Turning the superstructure engine off 437
load 529
Turntable assembly 160
Telescopic boom extension 830
Twisting caused by stretching in rotation-resistant
Telescopic boom extension 27
ropes and its remedy 1137
Telescopic boom 981
Two hook operation 539
Telescopic boom 27
Taking on a load 533
Telescopic boom distortion because of sunshine on
one si 530
Telescopic boom (T) 21 U
Telescoping 477 Unreeving the hoist rope 747, 805
Telescoping 739 Unreeving the hoist rope 805
Telescoping manually (emergency operation) 487 Unreeving the hook block 499
1182 LIEBHERR
Index
Update confirmation 1172 Warranted maximum sound power level (posi-

Update confirmation 1173 tion 77) 115
User interface 375, 381, 387 Weights 30, 644
Using the ladder 121 Welding work on the load 88
Unpinning / pinning the rope retaining pin 747 Wheel alignment 945
Wheel changes 1160
V Wheel checks 1159
Vehicle operating and control instruments 141 Wheel hubs 945
Vibration sensor 461 Which data is required by Liebherr Service? 1007
Vibrations 31 Winch 1, winch 2* 973
Visual check for damage 530 Winch 2 27
Visual inspection 1149 Winch brake 975
Winches 383
Waiting for the run-up phase 439
W Wind influences in crane operation 97
Warning marks “left” (position 3) 113 Wind influences during erection and take down 97
Warning marks “left” (position 98) 115 Wind influences when the “crane is not in
Warning marks “right” (position 4) 113 service” 97
Warning marks “right” (position 99) 116 Wind warning device 447
Warning note for unpinning the auxiliary boom on Wire rope 1127
the pul 103 Wire ropes and rope end connections 489, 1133
Warning notes 892 Wire ropes 489, 1146
Warning notes to unlock the auxiliary boom Working in the vicinity of electricity transmission
(position 6) 103 line 538
Warning of crushing danger for hands Working in the vicinity of transmitters 93
(position 32) 105 Working with a load 528
Warning of crushing danger (position 14) 104 Working with sliding beam monitoring 873
Warning of fatal electric shock (position 33) 114 Work on the crane superstructure or boom 67
Warning of high voltage (position 40) 105 Workplace-related emission value 30
Warning of rotating parts (position 31) 104 Work station - Driver's cab 167
Warning of suspended load (position 11) 104
Warning signs 103
LIEBHERR 1183

Bal - 17212-02-02 LTM 1220-5.2 G-12

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LIEBHERR

Mobile crane with telescopic boom

ORIGINAL OPERATING MANUAL

The operating manual is part of the crane!

It must always be available within reach!

The traffic regulations and those for crane operation

Liebherr-Werk Ehingen GmbH

Warn- Signal word Explanation

CAUTION Designates a dangerous situation, which can lead to slight or

ATTENTION Designates a dangerous situation, which can lead to property damage if it

Sign Signal word Explanation

Definition of directional data

1.00 Description of crane 19

1.02 Product description 24

1.03 Technical data 28

5 Workplace-related emission value 30

2.01 Traffic regulations 44

2.02 Break-in instructions 46

2.03 Job planning 48

1 Planning crane operation 49

2.04 General safety technical guidelines 50

3 Safety guidelines for ladders 57

4 Requirements of the crane operator 62

5 Selecting the location, illustrations 1 to 3 73

6 Slopes and excavations, illustrations 4 and 5 76

7 Permissible ground pressures 76

9 Checking the safety measures 82

10 Crane operation with a load 83

13 Crane operation in case of thunderstorms 88

14 Welding work on the load 88

15 Safety instructions for external power supply (230 V AC) 88

16 Endangering air traffic 89

17 Joint lifting of a load by several cranes 90

18 Working in the vicinity of transmitters 93

19 Hand signals for guidance 95

20 Beaufort Wind chart 95

21 Consideration of wind conditions 96

22 Interruption of crane operation 98

23 Taking up crane operation again 98

24 Ending crane operation 99

25 Turning / driving in reverse 99

26 Parking the vehicle 99

2.05 Signs on the crane 101

1 Warning signs 103

2 Command and prohibition signs 109

3 Notice signs 113

2.06 Antifall guards on the crane 117

1 Antifall guards on the crane 119

2 Fastening points 119

3 Attachment points on folding jib 121

4 Railings on the crane superstructure 125

5 Cranes with luffing* cab 127

1 Travel operation with dolly 129

3.00 Crane chassis operation 139

3.01 Operating and monitoring instruments on the crane chassis 140

1 Vehicle operating and control instruments 141

3.02 Turntable assembly 160

1 General checks before starting to drive 161

2 Work station - Driver's cab 167

3.03 Axle suspension system 172

2 Axle suspension system 175

3 Axle locking system 181

3.04 Travel operation 182